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Author Topic: 500 K cafe racer conversion - build thread  (Read 63172 times)

Offline Ewan 500 K1

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New Avon Roadriders
« Reply #75 on: July 31, 2013, 09:38:55 PM »
new rubber, shame the boys in the shop put the front one on the wrong way round :-\

next .. back to the tyre shop then ... the scary wiring loom renewal

« Last Edit: August 22, 2013, 02:59:44 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #76 on: July 31, 2013, 11:02:24 PM »
Wiring Loom Renewal Resources:

Wire, Bullet Connectors etc Suppiers:

http://kojaycat.co.uk/
http://www.autoelectricsupplies.co.uk/
http://www.vehicle-wiring-products.eu/VWP-onlinestore/home/homepage.php
http://www.sgmotorsport.co.uk/
http://stores.ebay.com/Atop-Authentic-Auction/PET-Expandable-Sleeving-/_i.html?_fsub=2578659015&_sid=879188535&_trksid=p4634.c0.m322

500 four Wiring Diagrams;

http://oldmanhonda.com/MC/wiring500.html
http://kojaycat.co.uk/epages/950000457.sf/en_GB/?ObjectPath=/Shops/950000457/Categories/Motorcycle_Wiring_Diagrams (this ones well worth the £15 it costs)
Clymer one, see picture below

Generic Wiring Diagrams

http://www.hondachopper.com/garage/simple_wiring_diagram/simple_wiring_diagram.html
http://www.ripper1.com/tech/wiring/wiring2.jpg
http://www.ripper1.com/tech/wiring/wiring1.jpg

How To Guides and Technical Stuff etc

http://www.sohc.co.uk/index.php?action=dlattach;topic=5432.0;attach=4217;image
Nice simple one on how to use tools and fix connectors etc
http://www.colorado.edu/physics/EducationIssues/podolefsky/electric_motorcycle_howto_wiring.html
The John Partridge one at:
http://www.triumphrat.net/twins-technical-talk/229345-idiots-guide-to-making-your-own-motorcycle-wiring-harness.html
Honda Motorcycle Electrics Manual:
http://minus.com/lbtlR5awJwSHPy

In General ~ but not always !

A RED wire is permanently live (+ve), ie 'hot wired' to the battery.
A BLACK wire is switched live, ie only +ve when you turn the ignition on.
A GREEN wire is permanently grounded (-ve). Ie at all times connected to the -ve terminal of the battery, via the frame.
A LIGHT GREEN wire is switched earth, ie only connected to the frame when you press the horn button.
« Last Edit: August 22, 2013, 02:59:01 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #77 on: August 05, 2013, 08:24:28 PM »
old loom a bit knackered and burnt at the edges;

« Last Edit: August 22, 2013, 02:58:30 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #78 on: August 05, 2013, 08:30:25 PM »
tools:

crimper £9 from VWP
Wire stripper / crimper £8 from Aldi  ::)
« Last Edit: August 22, 2013, 02:58:09 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #79 on: August 05, 2013, 08:35:14 PM »
stripping wire
« Last Edit: August 22, 2013, 02:57:45 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #80 on: August 05, 2013, 08:37:01 PM »
crimping
« Last Edit: August 22, 2013, 02:57:31 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #81 on: August 05, 2013, 08:40:31 PM »
crimped
« Last Edit: August 22, 2013, 02:56:58 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #82 on: August 05, 2013, 08:43:14 PM »
+ heat shrink sleeve
« Last Edit: August 22, 2013, 02:56:38 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #83 on: August 05, 2013, 08:44:58 PM »
+ plastic cover ... should be pretty secure now
« Last Edit: August 22, 2013, 02:56:18 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #84 on: August 05, 2013, 08:48:01 PM »
bodged battery holder for under the seat hump (cheers Mick  :P)
« Last Edit: August 22, 2013, 02:55:43 PM by Ewan 500 K »
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Offline Ewan 500 K1

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rewiring
« Reply #85 on: August 05, 2013, 08:51:20 PM »
new headlamp spaghetti and idiot lights
« Last Edit: August 22, 2013, 02:55:20 PM by Ewan 500 K »
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Offline Ewan 500 K1

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tank trim
« Reply #86 on: August 05, 2013, 08:53:24 PM »
Halfords Screen Trim used for tank trim (later .. Halfords are a rip off, you can get the same stuff for half the price off ebay)
« Last Edit: August 31, 2013, 01:25:01 AM by Ewan 500 K »
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Offline Ewan 500 K1

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Dual Discs
« Reply #87 on: August 05, 2013, 09:01:22 PM »
bit of a funny one when refining the dual discs set up today. The caliper arm for the additional disc on the right hand (speedo drive Side) was perfectly aligned with the disc without any need to mess around contrary to al expectation (photo one) (laterz... no thats wrong, See my seperate post at http://www.sohc.co.uk/index.php?topic=5571.msg27566#msg27566 for the pain and agony of setting up my dual discs )but the original set up on the left hand side was misaligned (second photo) and had to be brought into line by putting some washers in between the caliper arm an the fork.... although thinking about it now maybe the mudgaurd mounting bracket is supposed to go between the caliper arm and the fork leg. Just now I've got the caliper arm directy onto the foork with the mudguard bracket on top of the caliper arm.
« Last Edit: August 25, 2013, 06:54:59 PM by Ewan 500 K »
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Offline Ewan 500 K1

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Re: 500 K cafe racer conversion - build thread
« Reply #88 on: August 05, 2013, 09:04:21 PM »
so , thats it for now. Stuck the tank and seat back on and sat with a bottle of beer and a fag an just looked at it for a while....
Still to do ... finish the electrics, get a hold of longer rear shocks, buy some rearests, powder coat the frame and sort out the rear light / number plate set up
« Last Edit: August 05, 2013, 09:22:27 PM by Ewan 500 K »
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Offline Ewan 500 K1

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Re: 500 K cafe racer - new loom finished
« Reply #89 on: August 20, 2013, 09:51:46 PM »
New custom wiring loom all finished. Amazingly everything worked first time except the starter button which needed grounding to the frame. .. and the crappy mini  indicators that I got from HALFORDS, which blew the fuse and screwed the relay. Old indicators still working fine , so there must be a fault in the halfords ones, they have some bad reviews. Frame all stripped again ready to go and get powder coated. New fork seals arrived. Cant get new rear shocks from Hagon till end of September and Tarozzi are on holiday till Sept , so rearsets are on hold too. So near to finishing now ;)
« Last Edit: August 20, 2013, 10:06:04 PM by Ewan 500 K »
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500K1/550K3 mongrel cafe racer project for now at http://www.sohc.co.uk/index.php/topic,4120.0.html

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