The wiring is complete!
Since it's been a while since I've posted, I hope you'll forgive me an excessive number of pics this time.
I'll try to just hit on the highlights of the electrics.
The coils that came with the bike were toast, so I ordered a new set from Mike's XS. To mount the new coils, I fabbed a bracket from aluminum sheet metal. The bracket pieces were bent up and trial fitted to the frame:
Then the pieces were trimmed and drilled:
Riveted together, primed and mounted on the frame:
The stock controls were disassembled, cleaned and bead blasted. After blasting I clear coated the bare aluminum controls. I think the finish turned out really well:
The only modification I made to the controls was to add a ground wire to the start and horn buttons, since the bars were painted and I didn't think I would get a good ground through them.
I pretty much started from scratch and made up a new wiring harness:
If you recall from my seat thread, I built a fiberglass battery box to hide everything under the seat cowl. Here's the left side of the battery box with the fuse block, master relay and ignition coil relay installed:
The back side of the battery box holds a terminal strip for making wiring connections:
On the right side of the box the starter solenoid, radio shack rectifier mod and voltage regulator are installed:
Here's the front of the box showing the fuse block and the pigtail connection for the rear/brake light:
And a shot of the access to the fuse block with the seat pan installed:
From the battery box, the wiring follows along under the seat:
And along the left side of the frame to the headlight bucket:
Here's a shot of the right side of the frame, showing the ground connection to the upper motor mount:
I don't have a picture of it yet, but for the license plate light I bought a pair of the LED bolt lights. I don't like the way that the bolt lights shine on the plate at such a sharp angle, so I built a little bracket that will mount a single bolt light about 2-1/2" back from and below the center of the plate and shine up on it.
Well that's the wiring in a nutshell.
In the meantime I've also started the engine and have it running very nicely (at least at low to mid RPM's) after some initial troubles. I expect to have to do some rejetting for high RPM's.
I'm also almost finished with "take two" of my rear brake set-up. I'll get some pics of that up soon I hope.
Thanks, CC