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I Hope I Can Remember Where All Of These Wires Went

Oct 18, 2024

2 min read

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Not a problem, this is a piece of cake. After all, most of it is still in one piece on the floor. I just need to thread it back through the frame.



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As you can see below, I have installed the new Kill and Light switches to the bars. Add the new grips and electric throttle, and it's starting to look like a bike again.


I need to find the best location and way to mount the LCD screen and control pad for the bike's new systems. I was able to fit the control pad in the orange circle in the position where the old clutch lever was mounted. I did need to move the light switch out about 10 mm and just needed to drill a new hole in the bar for the locking pin on the light switch cluster to lock into.


As the wire between the Control Pad and LCD Screen isn't very long, I have placed the screen in the Green Circle above the ignition switch. I made a template with lightweight aluminum so that I can get the angle and spacing correct, as I will be bolting the mounting plate on the same fixing as the ignition switch assembly.



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Having acquired the template, I proceeded to create a new bracket using a 2 mm aluminum plate, which I then painted black to match the screen seamlessly.



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I have fitted the old front fairing to check clearances between the brackets and fairings from the switch gear on the bars.


I can now see that everything fits and nothing is hitting on the bracket or fairing. I can also see all of the wiring, which isn't a great look. I think I will make a dash panel to fit into this space.



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I located 3 bolt holes in the bracket that the original instrument cluster was fixed to. Using some cardboard, I have marked up a template that will be transferred onto some composite panel I have on hand.



The composite panel is white on one side and black on the other. I have obviously opted for the glossy black side.



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This is a much better look than the wires and relays behind the headlights. I have ordered a set of panel lights including indicators, high beam, and a couple of warning lights that I will mount into the new dash panel.


Now we are going to add the control wiring to tie the bike electrics to the EV electricals.

Oct 18, 2024

2 min read

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8

0

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