And Done

I'm calling her done - although is that really a thing? I had three great 20 minute-ish rides but now I've got to check for intake leaks - all of a sudden my RPMs won't go down after I blip the throttle.

But, here's "done" pictures and a video. I gotta say, I've very pleased with the result:

First Start and Ride!

The video is a bit shaky, but you can't recreate first ignition and ride! I'll post some finished pictures and a video walk around this weekend.

I'm a little concerned about my charging circuit, but I think it's fine. I'll also do further testing this weekend.

Final Wiring Diagrams

Here are my final wiring diagrams that I used. Although they are fairly specific to my needs, they might be helpful to someone else. Wiring is oddly one of my favorite parts - I like the puzzle aspect to it. Feel free to post questions or comments regarding what I did.

I think most of it is fairly non-controversial, but I'll make 2 comments: (1) someone else might not have included all three relays on the same battery hot wire. My thought was that only one of the relays would be pulling current at a time since I'll start the bike with the lights off. Thus, I didn't think separate power wires were necessary; (2) Reg/rec instructions usually suggest that you hook up the wire that provides current from the reg/rec to the battery directly to the battery's positive terminal. I don't like to do that because I like a fuse between the battery and the reg/rec in case the reg/rec fails to do its job and causes a current spike that damages the battery. So that is why I attached the reg/rec feed wire after the fuse on the same wire that goes from the battery to the ignition switch. This leave my ignition switch unfused, but nothing else.

When I draw up my diagrams I like to put the components roughly in the spots where they are on the bike. Sometimes that creates some space issues, but by the time I realize it it's really to late to do anything about it. So, I'll live with my charging and ignition components kind of being scrunched up.

we're at 99%!

I am all but done with the project - I just ran out of time this weekend to finish up.

The wiring and cables are all installed and working properly (although I haven't tested the charging or ignition circuits).

I was originally going to use the stock points ignition so I had to make room for the Alpha electronic ignition but it worked out. In an ideal world I wouldn't want the ignition module under the tank, but space is limited. Likewise, I wouldn't want my reg/rec right behind the engine, but that's where it fit best.

I just have to fit the gas lines and line up the airbox snorkels - for some reason they're not lining up. I'm sure I put one of the boots on wrong or something. The petcocks should work, but I'll have angle them backwards, even on the right hand side.

I had to make about a 2" spacer to attach the horn so it cleared the front engine cover but didn't hit the front forks.

It turns out the /2 clutch cable has the same amount of exposed cable as the /6 cable, so I didn't have to cut it down like I thought I would. I used Tom Cutter's clutch cable instructions found here to adjust the cable. Ultimately, I used /2 brake and clutch cables since I'm using the /2 hand controls but I had to use /6 throttle cables so they would attach to the /6 carbs. I though I would have to modify one or more cables, but they all worked great.

I installed one of Vech's Brown style side stands. I had to heat it and bend it out a bit to get a better angle, but it seems to work well.

I got some stainless r69s mufflers from Keihan Systems in England. They were great to deal with and had my mufflers at my door in just over a week. I'm sure I'll never see my original mufflers from Epco - that was a very disappointing realization. Now we just have to get Keihan to start making conversion headers.

Hopefully my next post will be of a first start video!