YEEEEE HARRRRR !!! IT LIVES

Posted: Sat Apr 11, 2015 10:56 pm

Today I finished off the last bit of rewiring my bike.
Put half an Imperial gallon of oil in.
Pulled the plugs out n put a good squirt of WD40 down the barrels.
Fitted the battery.
Switched on my ignition.
Pressed that little red button and churned it over for several minutes (To get the oil circulating around my motor).
I checked for a spark at my plugs while I did this bit, there was a bit of a sparkle there.
Put a gallon of 4 star in my tank, turned the tap to ON.
Churned it over several times more
then................IT FIRED UP, on all 4 pots Very Happy

My battery is completely fritzed, bought new 3 years ago, never been on the bike till today (Motobatt Gel battery about to be ordered).
My throttle cables are very stiff (need replacing).
Tick-over seems very high.
Rev counter isn't working (cable needs replacing)
No dial lights.
No brake lights, from front or back brake.
High beam is low and low beam is high and my dash board tell tail light matches, but the headlight works so it's a swapped wire at a plug
Tail lights work, front parking(?) light works.
Indicators flash left for left and right for right.

Posted: Sat Apr 11, 2015 11:15 pm

Congrats....a bit more tidying up to do with the wiring but she's a runner!!!

Posted: Sat Apr 11, 2015 11:32 pm

Excellent! Another one brought back to life!

Posted: Sun Apr 12, 2015 1:28 am

Good deal! I look forward to that day with my bike!

Posted: Sun Apr 12, 2015 2:33 am

Good job Simon! Get her sorted.......you got a rally to go to......

beerchug

Posted: Sun Apr 12, 2015 9:33 am

Good effort seeing you made your own wiring loom from scratch

Hawk Joined: Aug 17, 2013 Posts: 302 Location: Devon. UK

Hi Simon.

That's great news, you must be well chuffed.
It sounds like you've got the basics right and now just have a few details to sort.

So when's it going for an MOT ?? Smile

Posted: Thu Apr 16, 2015 9:35 pm

Stueecat wrote:

Hi Simon.

That's great news, you must be well chuffed.
It sounds like you've got the basics right and now just have a few details to sort.

So when's it going for an MOT ?? Smile

Chuffed? I'm like a dog with two tails Very Happy

Aye, a few details to sort, mainly things I hoped I'd get away with and a couple of errors Smile

MOT is booked for 10.30 next Friday now.
Followed by home, lunch, walk the dog, away to a rally on the bike, That's the plan anyway.

It was booked for 2.30 tomorrow, but that was wishful thinking.

Posted: Fri Apr 17, 2015 9:30 pm

I've solved all but one of my lighting problems, it was the earth (ground) connection at the plug for the right hand switch gear. As it was such an important connection, as well as crimping the connector I soldered it. I think that was the first one I did that with, and over soldered it due to being such a clumsy oaf. It is now good.
The one remaining electrical problem is the connector to my front brake light switch, the connector itself has broken. You'll remember that these are VERY short wires with a small female flat terminal in an insulating sleeve. The crimp is still on the wire. I'm looking forward to getting that off and getting connector one crimped on.

Dial lights work; brake lights work from the rear brake light switch; low beam is low, high beam is high and the high beam telltale agrees Smile

My rev counter works as well now and a new battery is ordered, a Motobatt Gel battery. I hope it gets here in time.
Motobatt batteries are our UK/European equivalent to US Big Crank, I think, it's even got the same 4 terminals Smile

The other big problem is my stiff throttle cables and due to that the very high tickover, 5,000rpm Shocked

I think part of the problem is that I've routed them wrongly.
I've got the old Eurosport throttle, where both cables exit from the top of my right side, one piece, switch and throttle body.
I've routed them around in front of my steering head and through that bent wire holder thingymajig on the left side of the steering head.
From there they go through that hole in the triangular frame stay and then down to my carbs.
They look to be pulled a bit tight and far to close to the front left tank support rubber.

I remember reading something about routing wiring a few months ago, but I can't find it now.
I'm wondering if there's a similar document about routing control cables, or if someone can simply tell me where I've gone wrong, please.

Hawk Joined: Aug 17, 2013 Posts: 302 Location: Devon. UK

Hi Simon.

Good work with the electrics. I think building a new loom from scratch is brilliant.

I've recently battled the same problem with the throttle cables on mine.
My best advice is to make sure the cables are lubricated properly, I used some light fork oil, and follow the routing guides completely.

the cable guide on the left side of the headstock that fits under the rubber tank mount is a wiring cable guide/clamp. The pics below are taken from an FZ manual. On later models the main wiring loom is on the right side of the headstock and that guide / clamp is used to secure the wiring loom for the fairing.

In the pictures it shows the throttle cables sitting on top of the tank rubber mount, when you're fitting the tank you can lift the cables over the tank mount so that once installed the cables are on top of the tank mount.

I did all this and my throttle now snaps shut properly.

Cheers Stu

Posted: Sat Apr 18, 2015 7:00 am

Looking good, and well done on doing your own harness. Out of interest, what are you and others using to attach your harness to the frame. The original wire bands start to look a bit ratty when undone and done back up a few times. I was going to simply use black plastic cable ties.

Chris

Hawk Joined: Aug 17, 2013 Posts: 302 Location: Devon. UK

Chris.

I pulled the rubber cover off the original ties, squashed the metal part flat in a vice, cleaned the rubber cover and put them back on. Failing that, black cable ties work and look ok, it just depends how far down the original route you want to go.

Stu

Posted: Sat Apr 18, 2015 10:25 pm

Me and a mate who came over to help, solved the throttle cable routeing problem, they now go as per these diagrams mainly because they've got to go that way or they're pulled too tight. Not quite 'snapping' shut, but at least I can now shut my throttle. A bit of tweaking will probably sort that.

Electrical wiring problem again though Sad

I had the unwrapped loom laid out along my frame, to test everything and have room to work when correcting any problems. I sorted out a couple of faults yesterday and everything worked perfectly. Another run through everything again this afternoon, EVERYthing worked correctly still Very Happy

So I disconnected it all, wrapped the loom, routed it inside my frame, tie-wrapped it up, headlamp shell fitted, plugged everything back in and ran another test.
No dial lights, indicators working but flashing diagonally opposite (sorted), then flashing the opposite way (sorted), but all the way through this my dash board repeaters
are flashing the opposite way to the switch position. AND when indicators are off both repeaters are on when my parking lights are on.
An earth fault. I've spent 2 hours going through all the connections to my lights and winkers.
I got my dials to light up and at the same time my indicator repeaters went dark but a moment later it reverted back to the fault.
I've gone over the plug and socket I was holding very carefully, I can't see any problem and despite pushing n pulling at every connector in that plug, I can't duplicate my fault clearing again. I've pushed n pulled at every connector, inspecting pins and sockets, every little thing. I can't find it n its doing my head in.

My bike started easily, with a jump off my car. Everything works properly, apart from this wiring earthing fault.
Motobatt gel battery ordered, I hope it gets here in time. -- MOT test booked for Friday 1030 morning.
It's a bike shop not purely a test centre, so I'll ask them to synchronise my carbs and see if they can trace the fault while they've got it.

Fridays plan
Up early, wash the bike.
Try n solve this fault.
MOT
Back home
Lunch, walk the dog.
RALLY Very Happy

Posted: Fri Apr 24, 2015 7:28 pm

MOT Test result

PASS

But the Mrs has had a bad turn. So I'm still at home, heading down to the rally tomorrow morning.

I've also solved those niggly bloody electrical faults. Not properly, but I know exactly what the problem is and will sort it properly next week.

All in all I'm well pleased Laughing

Posted: Sun Apr 26, 2015 11:28 pm

I got back from the Peevin Hoolits Club, SBPR Rally this evening. A 250 mile round trip.
She ran beautifully all the way, but I need to get my carbs synchronised.
On the way back North today I got a bit of everything weather wise. It would go from sunny but cold to rain for 5 miles or so, back to sunny for 10 miles or so. On top of the higher ground just South of Edinburgh I got sleet, then snow and passed a gritter salting the road Shocked

I checked my fuel mileage this trip.
61346 at the first fill up, 61562 at the last and I put a couple of gallons in mid trip.
216 miles, 2.01 (call that 2) and 3.3 - 5.3 Imperial Gallons (6.36 US Gallons) gives me 40.75 miles per gall (34 miles per US gal) Smile

That's a HUGE improvement over what I was getting, a full tank was going onto reserve at around 100 miles.
Synch'ing my carbs and a bit more mileage for everything to bed in properly will help some more.
I haven't done the relay mod yet. It's completed ready to go in, but I wanted to compare like with like before I did it.

I'll give it a good going over this week, make sure nothing fell off Surprised

There's a slight oil leak from my sump gasket, but I'm going to drop the oil and whip the sump off to see what my oil pick-up screen has collected. I'll inspect the faces and see if there's an obvious cause
There was a lot of black gasket goo pieces stuck in my oil screen, before I cleaned it up. I want to be absolutely certain there's no more floating around in my motor. It isn't that I think there can be any left in there, it's purely for my piece of mind.
I've got to finish off my wiring harness as well. There's that connector to replace then wrap or heat shrink the complete harness. It got a quick wrap last weekend so I could field test it this weekend. That ground connector failed me Sad

Not a bad result though.
The connector I've got to replace is the ground wire female pin for my dial and warning lights. I soldered all of the ground connectors, as well as crimping them. I think this was the first one I did, I got a bit too carried away and soldered the whole thing up Rolling Eyes

Posted: Mon Apr 27, 2015 12:04 am

PICS PLEASE! director

Posted: Mon Apr 27, 2015 7:08 pm

1100russ wrote:

PICS PLEASE! director

Here you are, taken in the rain a few minutes ago.
Click on the thumbnails to get the full size pics.

The W on my numberplate denotes the year she was first registered for the road.
From August 1 '80 through to August 1 '81, August 8 '80 for mine. Don't ask "why August?", I've no idea.
That chain is 100t moly-chrome slinging chain, hooked through the shackle of my home made ground anchor.
That sort of security is what's required around here, if you want to hang on to your stuff.

Posted: Mon Apr 27, 2015 10:08 pm

Sweet! Love the color. Looks good with the white wheels and the fork lowers painted too. Nice ride my friend!

beerchug

Posted: Mon Apr 27, 2015 11:01 pm

1100russ wrote:

Sweet! Love the color. Looks good with the white wheels and the fork lowers painted too. Nice ride my friend!

beerchug

Thanks

Posted: Tue Apr 28, 2015 12:47 am

Good job Simon, but I would hate to live somewhere were you have to bolt everything down because of shitheads wanting to pinch everything. I haven't locked my shed since I built it in 1980, wouldn't know where the keys are, and a few years ago there was a lot of bikes in there, only 6 there at the moment and a lot of people knew there was a lot of bikes in there

Posted: Tue Apr 28, 2015 9:32 pm

norm wrote:

Good job Simon, but I would hate to live somewhere were you have to bolt everything down because of shitheads wanting to pinch everything. I haven't locked my shed since I built it in 1980, wouldn't know where the keys are, and a few years ago there was a lot of bikes in there, only 6 there at the moment and a lot of people knew there was a lot of bikes in there

Thanks

This is modern Britain, our car insurance is low here because it's classed as a 'low risk' area.
Even so, if you don't take 'reasonable precautions' you'll get a reduced pay out if the local shitheads pinch it.
I've lived here most of my life, I'm used to it unfortunately.

These days, at the really big rallies, like The Farmyard Party or The Bull Dog Bash etc, where there are several thousand punters. There are "bikers" who'll steal from other bikers Embarassed

That should never ever have become a concern, but it is Embarassed