1984 Katana 7/11

[pete]

Pretty sure I posted this earlier in the thread but I'm too lazy to go looking now... I'll get the tank repaired professionally and then this is the plan for the colour scheme except with a black motor:

Mock Up 1 by starpoint73, on Flickr

[dorkburger]

Tasty........ I like it.

[pete]

Cheers, me too!

[pete]

Not a huge amount of progress but the cush drive rubbers arrived and are in, and I got a rear disc yesterday so that's on with some temporary bolts (I need to get proper caliper bolts too).

Untitled by starpoint73, on Flickr

I've been doing a bit of standing around trying to find a starting point for the harness.

Spent 5 minutes making a bracket for the headlight relays.

Untitled by starpoint73, on Flickr

I cleaned up the dodgy aluminium welding somewhat on the battery/electrics tray and it's in so I can work out where all the bits need to go. I'll mock up a Shorai battery to stick in there also.

Untitled by starpoint73, on Flickr

[thebrandonbeezy]

Things are moving rather quickly now Pete!!!!

[pete]

Sure are! Hopefully I can keep some momentum going although getting started on this harness is throwing me a bit... never done a made from scratch one before so getting the starting point is a challenge. Might just have to start laying down some wire instead of over thinking it. I've managed to drain the Kat fund temporarily with all this recent progress so time to go back to working on stuff I've got half finished or at least have the bits to start.

[pete]

Got a bit further along yesterday... bit hard to get pic's of the progress when it's drilling holes but here's what I got.

Relays, fuse box, and starter solenoid all mounted up. The R/R will go underneath the tray once I get a chance to steal the SH775 from the 450 for 10 minutes to work out the location. I have a mock up Shorai battery in there also.

Untitled by starpoint73, on Flickr

All the electrical bits at the rear mounted up temporarily including the number plate mounting bolt LED's.

Untitled by starpoint73, on Flickr

Now I'm trying to figure out the front indicator mounting. I had a closer look at another fella's Kat on Saturday who has his indicators mounted from the frame rails, and my frame doesn't have the same mounts available as his, so there's no support available out along the vertical frame rails.

I basically ended up with two options... a bar across the front from the horn mount or a bracket on each side coming down from the front cowling subframe mounts.

I think the bracket on each side will be neater and I reckon I can squeeze a nut in behind the bottom of the mounts on the frame so each bracket would have two mount points, however I'm not convinced there won't be too much flex with that setup.

The alternative would be a P clamp around the vertical frame rail, but there's a welded seem on the inside that might make a P clamp a bit tricky to use. I also havent' found any that are wide enough to take the 10mm threaded end of the indicators.

I have enough 2.5mm thick aluminium around to make two brackets, so I might just make one up and see how it feels. There's no bending involved so there's no reason vibration should be an issue for the aluminium strength/cracking wise.

Untitled by starpoint73, on Flickr

[pete]

Front indicator mounts sorted. Definitely need to smooth and reshape a little and they'll need to be satin black, but the idea works. They'll be better with a second bolt through the bottom of the cowling subframe bracket though.

I've made a rectangular hole in them the same as the rear mounts so I can use the mounting rubbers, and a second piece of the 2.5mm aluminium behind the brackets makes the right width so they bolt in nicely too.

My paranoia made me check the ADR's for the mounting location and as far as I can tell they'll be fine... 600mm above the ground and 320mm apart. There's a requirement for viewing 20 degrees inwards, however there's no way the stock Kat indicators would meet that anyway, so I don't think that's of concern. These are also the current ADR's which technically don't apply...

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

[pete]

Spaghetti anyone?

All the main wiring is laid out, time to start doing the short runs between the fuse box and relays.

Then I can do some splices off the main runs to get to all the components.

I still need to sort the location for the USB charger I want in there as a just in case for my phone or GoPro too.

I also need to put some rubber under the fuse box and relays. While none of the fuse holders or spade terminals in the fuse box touch the tray it's a bit close for comfort so I want some insulating material just in case. The relay wiring will come out underneath at a 90 degree angle so same deal there.

Untitled by starpoint73, on Flickr

[pete]

My inner post whore requires I post something even though I don't have much to show. Haven't had a heap of time and this harness is proving slow work as I work out how I need to run the wires and plan for splices etc.

While I had the 450 apart for servicing on the weekend I took the SH775 R/R out and worked out the mounting. I need to move the fuse box a bit to cater for it and the connectors underneath.

Harness wise I've laid down all the main runs and have cut lengths for some of the splices off to the components. I've started on simple stuff like the horn circuit which comprises the purple wires below.

Untitled by starpoint73, on Flickr

High and low beam connections done to the relays.

Untitled by starpoint73, on Flickr

I didn't get pic's of the two others but the indicator relay connector is on the splices but I haven't connected it to the main runs yet, and the side cover accessory switch is sorted also.

Much work to do... a bit at a time and it'll be a complete wiring harness before you know it!

[pete]

Still looks like a bunch of spaghetti but it's getting there. Most of the left side terminations and splices are done now along with most in the electrics tray.

I need to figure out where I'm running the control block wires so I can terminate those, then that'll be the bulk of it, the right side doesn't have as much as the left.

I had to do some revisions of the diagram after realising some things running up either side of the frame ended in the same connector... meaning it would be a little impossible to remove the harness without taking the pins out of the connectors.

Untitled by starpoint73, on Flickr

[pete]

This doesn't look particularly exciting, but for me it is!

https://www.youtube.com/watch?v=qvfX2_2CPCo&feature=youtu.be

The other front indicator doesn't have a working bulb so I just chucked that one on.

The left side is all but terminated and I started bundling the wires last night as well. I've got some extra wire length to neaten up yet though. There's just the oil pressure switch and neutral switch to get terminated, and of course I can't do the dash end until I get that purchased later on.

Untitled by starpoint73, on Flickr

[Big Rich]

Haven't checked in for a while Pete - sorry. Everything is looking great though!

Good luck on your wiring.....thats a job that can make your eyes cross.

[nvr2old]

Yeah, electricity always has been and always will be a foreign language to me.."look at it as running water, Larry..wah wa, wah wah wa.." I admire your stick-to-it-ness, Pete.

[steve murdoch]

I'm with you on that, Larry.
The proper spelling of the word electrics is "Kryptonite".