TOPIC:

More work on the loom. Found somewhere for the RFID Receiver - need to weld on a tab but it will be behind the battery under the tail section. Got the coils in place and the Dyna S wired up. Waiting for some copper mesh for the switch block and indicator wiring so I don't have any crazy switch problems due to how close the 22 gauge wires are to the plug leads. Should hopefully have the front end wired up and tested by the end of the week.

 

 

 

Prrrdeee!!! I like the plastic standoffs on the coil mounts. 

It's been a few weeks since I posted. I've been working away on the electrics but have been pretty busy at work so it was slow going.

I have everything except the rear indicators done. They will hopefully arrive this week. I wanted to use combination indicators (tail light, brake light and indicator) but I am only allowed a single brake light. Dual brake lights are only allowed on the newer bikes that have to meet the EC standards. The old German standard is a bit more relaxed as far as indicators go, but it restricts bikes to a single brake light. TL-DR: I sent the combination indicators back and got an LED strip for the tail.

It's a pretty tight fit under the seat, but it should tidy up when I wrap the loom. 

  


Spark plug leads are done. They wrap around the frame up the front to keep them as far as possible from the rest of the wiring. I will probably put some rubber around the frame or sheaths on the leads so they don't wearover time and short out.

 

 


I need to make a backing plate for the tail light - the screws are only temporary. I figure I'll make a plate out of some thin sheet metal and glue it to the tail. Then I can screw the light to the plate. It should also provide a good backing for some bog so I can tidy up the cutout (which still needs some shaping).

 

 

Coming along nicely Callum, the wiring is always a bit of a fight when you are "scratch building" a loom but it looks like you are getting there.

I've been trying to get the electrics done on this thing so I can finish up the rest of the parts and finally get around to painting...
I'm currently trying to figure out how to get a good, reliable ground connection to the frame from a kill switch. The switch will be mounted to a 3mm aluminium bracket that will be screwed to the frame. I would like to have more that just the threads of the screws connecting the kill switch but don't want any unpainted steel under the bracket that could rust... I thought about some brass inserts or studs for the bracket and also for the main ground cable going to the engine. I figure they would need to be braized to the frame so I don't have any problems with corrosion between the inserts/studs and the frame.

I'm probably overthinking this, but I recently spent some time stranded at work due to a bad ground (corroded threads).

Why ground to the frame ? Not sure of your set up but is running a 14gauge common ground cable through your loom ( if it's not taped yet) back to the battery neg terminal a viable option. That way only the engine would be chassis grounded ?

I do have a common ground, and a 10mm2 cable going to the engine. I just figured if I set up the frame with a reliable ground it might make life easier if I change things around down the road.

I'll probably just end up bolting the common ground, rectifier and engine ground directly to the kill switch bracket.

Got the exhaust hanger and the low-beam switch done this weekend. Copied the exhaust hanger from Doctorot's build (thanks for the photos!). It's a bit longer than planned as the new exhaust is a lot lower. 

   

 

  

  

  


Just clears the rear master cylinder...

 

  

May i ask, from what bike the rear MC came off?

Not off a specific bike: www.webike.de/products/21203072.html

The paint on your 'zorst looks fantastic. What is it?

Couldn't tell you, sorry. It's a replica of the Kerker system used on the S1. Came from Japan but I'm not sure who makes them (got it through a place I deal with here in Germany).