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Old December 2nd, 2019, 09:53 AM   #41
65Mulberry
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Ran into a starter gear issue that i got resolved last PM... bike is turning over great now...
also mounted the 2.25" mini gauge on handlebars...going to splice in an old factory gauge cluster harness plug after I get the schematics rung out-- for all the dash lights and indicators etc....
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File Type: jpg IMG_4227.jpg (107.9 KB, 8 views)
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File Type: jpeg image0 (1).jpeg (95.9 KB, 9 views)
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Old December 2nd, 2019, 11:19 AM   #42
65Mulberry
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original Li Ion batt Danny XYZ pointed me toward is discontinued but this one is avil w/same specs:
4 cell, 6amp hr, 120CCA

Actually fits my avail space even better anyways... anybody see an issue with using it?

1.25" thick and less than 5'x4' HxW... claims 14oz
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Old December 2nd, 2019, 03:38 PM   #43
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Note that Antigravity "small case" batteries only have BMS circuitry for balance-charging. They do NOT have overcharge and over-discharge protection! Overcharging can be handled by factory VRM/RR. Measure output and verify RR doesn't output more than 15.5v.

Over-discharge protection must be manually done. DO NOT leave bike with lights on and engine not running. Such as using kill-switch instead of ignition-switch. ALWAYS use ignition-switch to turn OFF to prevent ever leaving lights on. This can deeply discharge small battery within minutes and destroy it (even lead-acid batteries).

A LOT of small lithium batteries in market are configured like this, so care must be taken with their charging and discharging to prevent damage.

Last futzed with by DannoXYZ; December 3rd, 2019 at 11:58 AM.
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Old December 2nd, 2019, 04:16 PM   #44
65Mulberry
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I assume youíre talking about =\< 15v at the RR...While the bike is running/charging...?
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Old December 2nd, 2019, 04:44 PM   #45
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Quote:
Originally Posted by 65Mulberry View Post
I assume you’re talking about =\< 15v at the RR...While the bike is running/charging...?
yes, rev bike up to 4-6k-rpms and note output voltage at battery terminals. This shows what's being pumped into battery to re-charge. Does it rise from idle to a stable voltage? or does it continue to rise with RPMs?

Last futzed with by DannoXYZ; December 3rd, 2019 at 11:57 AM.
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Old December 3rd, 2019, 10:40 AM   #46
65Mulberry
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gotcha... testing out coils, and electrical this week to hopefully start it by weekend.
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Old December 7th, 2019, 07:43 AM   #47
65Mulberry
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This morningís projectó merging/soldering the OEM wiring harness plugs for the speedometer and instrument panel to this small round oneó so that I can plug it in nicely and cleanly rather than cob it together..
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Old December 7th, 2019, 07:52 AM   #48
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Old December 7th, 2019, 07:25 PM   #49
65Mulberry
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Got new mini gauge sorted and soldered, spliced and heat shrink wrapped into OEM wiring harness so can use the factory plugs to keep things clean . I will have to decide how to handle temp gauge and low oil pressure light.. going see if I can find/fab a temp gauge housing for OEM gauge and prob just use a red LED light for an indicator for the oil since it’s on/off based on sensor signal.
I’ll clean out any/all of extra unused wires after testing and determining all is functional

Hope to plug it in see what happens next couple days... ����
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Old December 8th, 2019, 06:16 PM   #50
65Mulberry
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Looks like everything is good to go on the gaugeÖ The only thing I canít check is the highbeam but I donít have the headlight hooked in yet either... so thereís that
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File Type: jpg E486BC6A-23A3-4E91-89F7-7CD70E0E3F8F.jpg (41.7 KB, 1 views)
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Old December 11th, 2019, 12:37 PM   #51
65Mulberry
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Having a no-spark issue with good coils and good plugs. But I've traced it to a wiring foible in the harness from not using all of the original gauges... I've got an open ground from something that used to go through either the tachometer or the neutral light indicator circuit causing the neutral lock-out (clutch switch) to not work right. Going to ring it out next couple days, keep y'all posted....
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Old December 27th, 2019, 01:48 PM   #52
65Mulberry
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Itís ALIVE....
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Old December 27th, 2019, 02:36 PM   #53
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Woo hoo!!! Good job!!!
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Old January 1st, 2020, 01:51 PM   #54
65Mulberry
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Got my LED tail light and turn signal combo wired into the stock wiring harness plug now I just have to build a bracket to mount it on the motorcycle.
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Old January 1st, 2020, 01:55 PM   #55
65Mulberry
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Aaaaand finallyÖ Maiden voyage! 3 years later... 😂
Fitting that it took place on the first day of a new year!!
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Old March 18th, 2020, 06:27 AM   #56
65Mulberry
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So after a few months off the project.... Finally got back to it. I got the battery box fabbed up —had to move a few more electronics further up under the seat Which actually turned out better anyways. I still need to fab a bracket for tail-light assembly and revisit the guage situation
Headed to paint shop pretty soon...
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Old March 18th, 2020, 06:41 AM   #57
65Mulberry
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Also fabbed up a muffler bracket out of some aluminum plate. Just painted it satin black for now I think it should work OK it bolted right onto the relocated stock rear passenger peg mount
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Old March 18th, 2020, 11:53 AM   #58
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You're getting pretty good at this stuff.
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Old April 8th, 2020, 02:55 PM   #59
65Mulberry
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Got the rear brake fluid reservoir hacked back on the EASY way this weekend... I cut about 1/2" off the hose from it to master cylinder and clamped reservoir back on which put it at exact position to use an old fairing clip flattened out and painted black as a mini-bracket!

Also switched the exhaust back to the OEM dual header and put on a set of old Cobra F1-R slip-ons I had sitting around here... ran HORRIBLE at first (which i anticipated anyways because I did the Oft Forbidden & Maligned Pod Filter Swap. ) It fell off flat died out at 7k RPMs. So I slid #4 washers under needles successively til 3 worked great and turned mixture screws 2.25 out and now it idles, accelerates, and runs like a dream !! super crisp throttle response. Did a few WO throttle chops while I messed with things and the spark plug checks showed a perfect burn on plugs. So we'll see how that goes.

Pulls really REALLY good too from 3000-to redline... so I'm pleased with that so far. Felt more like a 300-350cc really--mainly due to the 35-40 lbs I pulled off it I think. But I am truly pleased and a bit surprised with the acceleration and how hard it pulls compared to the many stock and modified EX250's I've been on. I'll look through my pile of front/rear sprockets next to see where I want to end up with that as well. Watch the video here to see the throttle response--you can see the cable pulling throttle plate and hear it rev--I'm pleased.

First ride down the highway at 70-75 mph it was stable as a rock and rode great. Suprised how little wind buffeting for a naked bike too... I think riding position takes care of most of that. Had previously only been on 15-45mph cruises around neighborhood.

Also got the headlight sorted out and working too... one bad plug and two burnt fuses later.. and got the front LED mini turn-signals hooked up too.

So then I took 45 mins of quarantine time and rerouted and retucked and rewrapped all the wiring-- what little is left that is.

PS: Had my free leftover eBay integrated tail light/turn-signal/plate holder wired up and mounted with a bracket I built but the solder joints were broken loose and lost the running lights on it. not worth fixing really so I Got another on the way to replace it... I'll cover that little build in the next post update.

image3.jpeg

image2 (3).jpeg

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Old April 13th, 2020, 07:27 PM   #60
65Mulberry
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Got the new integrated taillight & signals mounted. Looks good and works great. Also making a thin aluminum plate to mount under the seat and above the taillight assembly. Iíve mocked it up here with black cardboard. When itís done and painted I will rivet it to bottom of seat ówill clean up the tail better
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Old April 13th, 2020, 07:36 PM   #61
65Mulberry
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More pics
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Old April 13th, 2020, 07:38 PM   #62
65Mulberry
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Couple more
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Old May 21st, 2020, 07:58 AM   #63
65Mulberry
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About done....FINALLY!!!

Few little odds and ends to trim out yet. Tank will be red to match seat as well... runs awesome too!
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Old May 21st, 2020, 08:52 AM   #64
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Old May 21st, 2020, 09:57 AM   #65
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Ooh Ah... very nice, very nice....

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Old July 2nd, 2020, 03:51 PM   #66
65Mulberry
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Finally got tank painted in Satin black with new graphics... 98% done
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