Fuse Panel and My various DIY Electrical Projects - PICS

Volume 1 - Chapter 1: Installing the modern fuse panel purchased from Chacal

I opt'ed to purchase the:
* Fuse Panel with normal fuses
* Wiring Kit (with correct colored wires and connectors)
* Fuse Panel Bottom Gasket (bottom of fuse panel is open)
* Seat Spacer Kit - Not exactly sure if I needed it but it was recommended for my model - This came with a location diagram
* Fuse Panel layout template





If you have ever stripped wire and crimped on a connector, you could do this project without any problems. If not, practice or get some help!

One the first night before it got to dark, cold and buggy I completed 85% of the project. I still need to wrap the wires, seal the fuse panel better and position the wires for long term use/storage. All circuits are functioning w/o any popped fuses on the first try. WOOT!

The pictures below mostly tell the story. I did shrink wrap all the butt connectors and added an anti-oxidant black type grease to each wire I crimped. I'm not sure if its the same as dielectric grease, but it is meant to prevent oxidation of aluminum connectors (and wires). So I figure it's better than nothing. I basically kept the fuse panel in the stock position. It will probably stay there unless I have a pinching problem after properly wrapping all the wires.

FYI: I'm not expert electrician or wire crimper, but I get the job done.

Note: The pictures below are probably out of order. Time permitting I will edit my post with Chap. 2.























After "cleaning up" the fuse panel installation, I intent to install some new horns using one of the extra 10A fuses and a relay. I'm not sure if that will happen before or after I check the alternator brushes.

Future volumes will include a semi-custom LED tail light & license plate conversion, an LED driving light set I'll piece together from cheap parts from Walmart and Ebay, a vintage fairing install/wiring and (hopefully) an upgraded headlight with a flashing modulator. Time and money permiting, all of the indicator lights will also be converted to LED in my "atari".

See my signature link for some info about how I rewired my Vetter trunk with modern LED tail/brake lights.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 1 - Chapter 2: Cleaning up the new fuse panel wiring

While working on tiding up the wiring:
* I decided not to add any extra sealant to the bottom or top of the fuse panel. A closer look at it, shows it is designed to breathe, even if it was never designed for a motorcycle.
* I changed the final order of the wires/fuses after some fit issues after all the wires were retaped, sprial loomed and placed.

Other than that the 2nd part of the project went as expected. I may not end up with "hidden" wires in the end, but I do want cleanly sealed, taped and positioned wires when I'm all done.









Any minor adjustments to the new loom sections will be done when I install my new horns and use one of the extra fuses.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 2 - Chapter 1: Installing Fiamm Freeway Blaster Horns

Though I did not make much progress on my initial day, I did get a good mental idea how and where all the wires will go. I'm not sure where the new horn relay will go just yet though.

My intent is for all of these projects is to update/modernize the electronics, wires and/or connector. Yet at the same time, I hope to make all the new parts easily removable for future replacement and/or factory-like restoration for some future owner.

That being said, I added bullet connectors to the pink horn button wire. This will allow me to rewire it into the new relay and totally disconnect it from the wiring harness.

New Battery + 14 gage wire will be ran to the fuse panel with a 20A fuse. All new 14 gage + & - wires will be ran to the new horns. The horn button to relay will new also, probably using 16 gage.

I've purchased BLUE for + to the new horns. This is not stock color. I have access to stock-like brown. I'm just not sure what color I want yet.

The pictures below show the initial prep work I did on the horn button wire. Its not alot but I damaged my gas tank and was side tracked getting it rewired.








Volume 2 - Chapter 2: Some Fairing Prep work

Though this does not exactly show horn installation, the horns will eventually be mounted on the fairing's bracket. Since I ran out of paint and need to sand the runs (and let it dry/cure), the fairing bracket installation will probably have to wait a while longer.




Volume 2 - Chapter 3: More prep works and rerouting my clutch cable

WTF am I doing rerouting my clutch cable? Well I didn't like the way/place in which it was laying under the gas tank. Also there was some wear on the cable's out sleeve near the tank.



A helpful tip that is probably not new:
Use some old/extra wiring to layout your project wire locations/lengths. Then you can cut the wires, crimp and heat shrink them in the house at night.

(Oh yeah I don't have a garage )

 

Re: My DIY Electrical Projects - Hope to help the new/timid

NOTE: The vinyl tubing I used to make the horn's wiring harness, was purchased from Lowes (near the plumbing dept. for $0.25/foot).



Volume 2 - Chapter 4: Custom Wiring Harness and Testing

Today I cut all my wires to length, per the scrap wires I cut last night. I started putting on connectors and shrink wrap. I went out to check the length of the (+) wire from the battery to the fuse panel.

While I was looking at it, I figured why not make a full custom wiring harness for the horns. I did this while I still had connectors on only ONE end of the wires (or none). This made the project possible with the solid & uncut tubing I bought the other day for this type of use.

The wiring harness assembly went rather smoothly. Some little soap water helped me pull 4 wires at a time thru part of the harness. Luckily I caught the missing fuse panel to relay wire before I began final assembly.

I may add some more tubing/tape to "T" the wire off shoots, but that will happen later.

Per another topic where I was confused about how to actually hook up the relay and the horn button:

Which lead to the plain English directions (for THIS relay & Neg/Ground activated horn switch).

Following Diagram B:
Snip Pink wire coming FROM the horn button and connect it to relay. #85
Run (+) from (new) 20A fuse panel connection to 2 places on relay. #86 #30
Run Wire from #87 towards horns - Split for both horns (This relay has two #87)
Run Ground (-) wires back from both horns to common ground or battery terminal (my intent).
Reconnect battery and insert fuse then LOUD fracking horns!

Now for my pictures and some before and after videos.







LOL - I didn't take any pictures of the horns or them test connected. Regardless here are before and after (test) videos.
http://www.youtube.com/watch?v=7Pu0XMMio78
http://www.youtube.com/watch?v=Iz61od-9kgw

NOTE: The Fiamm's do not fit the frame by default, but they will fit my fairing bracket which I had hoped would already be installed.

EDIT:
Got crazy and painted the horns and their brackets.



Volume 2 - Chapter 5: Horns installed and working

Short video showing installed horns working

Since my fairing needs alot of cleaning and electrical work, I decided to temporarily install my horns onto the frame. I did not have bolts short enough on hand, so I used two long bolts with lots of spacers. I also had to put blue loctite onto the back of the horns because the studs are to short to use lockwashers. Also I didn't have appropriate nylon lock nuts on hand.

The horns DO work w/o the bike running, assuming the battery is charged enough. Earlier tests were done with an undercharged battery.

The horns are LOUD with/without the engine running 0/55mph - It doesn't matter they are LOUD - Perhaps to loud, but if I NEED to use them I will be heard!

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 3 - Chapter 1: Additional side turn signal bars

In an attempt to make my self more visible and continue to add more LED, I found some inexpensive Amber LED light strips. They will be mounted on the top of my hard Vetter saddle bags and will have quick connect bullets for removal with the bags. The wiring will simply be spliced into the existing rear signals. They will only be on while the signal blinks.

Its a bit excessive, but I hope to be more visible to higher up drivers (semis, SUVs, etc), side/perpendicular traffic, distracted drivers and/or anyone who can't see my stock blinkers for whatever reason.

I need another nice day to complete the painting of the parts I want to do as well as attaching them to the bags and wiring.





FYI: The amber signals came from Amazon with free shipping: Wolo WTB-20. WTB-10 are the red ones but they are out of stock for most vendors or overprice (before shipping).

P.S. Two wire single intensity lights.

Volume 3 - Chapter 2: More prep work and painting

A few more layers of paint on the light housing and installation of the mounting brackets. I'm using the included mounting brackets as well as 3M molding tape. The tape will not stick very well to the PE plastic the saddle bags are made of, but I figured it couldn't hurt to have it present.



EDIT: Here is a short video of the light bars in action with the bike running.

Video of Light Bars in action

Wiring is not complete, but I did take a ride today with the 22g wires pushed into some bullet connectors for the rear turn signals.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 4 - Chapter 1: Semi-custom LED aux lights

Finally Installed 11/10/10 - Need to test at night next

Slight grinding of the housing and test fit of the LED H3 bulbs I purchased showed that the bulbs are to long. I'm currently trying to win some cheaper/shorter bulbs with less LEDs so they will fit.

EDIT: Waiting on ebay parts from asia. I hope THIS set fits...

EDIT 2: 2nd set of LED lights showed up from Asia today. They work and fit great. I still need to figure out how/where to mount them, but that will depend on the fairing install.

EDIT 3: I have started a seperate thread but will post finished info here as well.
http://xjbikes.com/Forums/viewtopic/t=28766.html

EDIT 4: Finally Installed and awaiting a night test ride.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 5 - Chapter 1: Semi-custom LED taillight cluster & LED plate bolts

Coming soon - I may end up ordering different tail lights if the custom install will not be as secure as I imaged it. EDIT: Test fitting of my LED cluster in a slightly different place proved promising.

LED plate bolts received via Ebay from Asia. They work with my tester. They seem plenty bright. Picture later or when I install them.


I made a custom 1157 socket with 3x 16 gauge wires, so I could plug my LED plate bolts into one of my tail lights soon-to-be-unused sockets.

Being my 2nd attempt at making the socket I learned a few things and changed my method.

I soldered the ground wire on the INSIDE of the socket shell. Then I heat shrank the ground wire. I stripped the two wires and double heat shrank the ends (for thickness). The wires were snipped to the minimal length so they just barely stuck out of the contact holes. Then I soldered them up. I got lucky on the first tries and got near perfect contacts made. I will fill the socket shell with silicone and shrink wrap the wires next.

To make the socket shell I started with a used 1157 bulb. I pull out the glass bulb and ground out the glue used to seal/secure it. Then I heated up the contact point's solder until the tiny wires dropped off. Then I cleaned up the holes with a small drill bit.

I did get a quote from a company I've made led purchases from. Unfortunately they cost ship was more than the part, and it made more sense to just try to make my own.

EDIT: No pictures yet because I did a fast/crap job in the dark. The custom L-Bracket install of the taillight is complete.

The LED plate bolts are installed and will NOT be wired into an 1157 socket as I planned. It will just be simpler and cleaner to tap into the harness wires.

Future pictures will show that I drilled thru the tool holder (hidden under rear of seat), to feed the bolt wires thru cleanly. Eventually I will properly splice them into the wiring. (I had to use twist and electrical tape in a frustrated hurry in the dark).

The LED plate bolts are bright but do not illuminate as much as the plate as desired. Technically I should be legal, so that will be good enough for now!!!

FYI: I haven't ridden since this install, so I'm not sure if the tail light velcro is still holding. Busy prior weekend and end of this week coming up.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 6 - Chapter 1: Vetter Windjammer V install

Coming eventually. This project may lead to a headlight upgrade as well.

A test fit of the bracket and fairing proved I have the correct bracket. I'm considering moving the fairing forward 1-2 inches so I can leave my stock headlight on the bike. I'd prefer that so I could leave all the wires in there.

Looking at my bird's nest of fairing wires, I'll probably start all over with new wires/sockets. I'm also looking for replacement signal bulb sockets.

EDIT:
I picked up a White Windjammer 3 and another white luggage set. A brief inspection of that fairing leads me to believe it may be in the best shape of all 3 fairing I now have. I still have some cleaning up of the wiring to do. I will also move the fairing forward those couple inches as planned.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

Volume 7 - Chapter 1: LED light upgrade inside my 82 Maxim Atari cluster

This should be a relatively cheap project. I do want/need to better seal the faceplate and "pretty up" the outer housing. The project will probably happen before or during fairing install if I have all parts in hand.

EDIT:
I now have an extra complete Atari assembly to play with. So I'll pull it apart to make sure I order the best and correct number of bulbs.

EDIT 2:
LED cluster bulbs ordered along with a LED brake light flasher and some LED RED side markers for my Hard Trunk.

Hopefully I can install many projects/parts all at once, or at least only disassemble the bike once (and let it sit while working on it).

EDIT 3:
LED bulbs arrived in the mail today. All worked with my tester. The fit is looser than stock bulbs. The amber turn signal bulbs are really loose. So I will probably install all 7 bulbs with a little bit of silicone adhesive.

I purchased RED leds for the SPEEDO/Tac. They look great on my spare/parts atari. I may want to modify the guts to better illuminate the low speed numbers (0-30). That depends on how well it lights up my GOOD atari cluster.

EDIT 4: Pics





Edit 5:
Atari Cluster Post
I created a separate cluster post for those only interested in the LED upgrade.
I took the entire cluster apart; cleaned it; spray painted the inside of the gauge shell; Siliconed all 7 of the lights into place.
Daytime testing showed the colored indication lights work. I'll have to test the gauge lights tonight.

 

Re: My DIY Electrical Projects - LOTS of thumbnail picture l

Horns finally installed onto the frame - Will be moved to fairing support bracket eventually.

Additional Volumes/Chapters posted.

I'm in the middle of several projects and the rest have been planned out (in my head) and in the posts above.

I'd really like to get all of these projects done ASAP and before the Dec 5th Toys for Tots ride in Chicago.

I'm still including lots of WIP picture for the anal retentive, OCD and curious people.

 

Re: My DIY Electrical Projects - Hope to help the new/timid

I am new to this site, I need some help with this 82' Maxim 750 we hard tailed, bobbed... I am having a hell of a time figuring out the spaghetti soup. I did away with ALL gauges in cluster and trying to hook break, runner, blinkers and head lamp functional. Does anyone have a wiring diagram to share or advice? I'm jonesing!

thanks

 

Re: My DIY Electrical Projects - LOTS of thumbnail picture links

@ tattoo, here is the minimum schematic..

http://www.currentobservations.us/image ... Series.jpg

 

Re: My DIY Electrical Projects - LOTS of thumbnail picture links

Tatoo I have not done the minimal wiring project and probably won't any time soon. Being my first bike I appreciate the safety features.

However, the minimal schematic is rather basic. It may be better in your original post to ask specific questions.

I'm guessing most people who did the minimal project didn't give it a second thought and just did it w/o pictures. But they may be able to give pointers and stuff.

That being said: You probably could/should start a new fuse panel and if installing modern horns be sure to use a relay and a separate fuse.

P.S. After rereading your post above. If you have the bike apart anyways, totally remove (but save) the spaghetti wiring harness and connectors. Then look at the basic diagram and just figure out the very limited amount of wiring you will need and reuse "engine electrics" as needed from the original harness. I'm not sure its a Level 1 easy project, but it should be around a 3.

Of course if I did do this project I'd get carried away and make a new wrapped harness and other bells and whistles.

 

Re: My DIY Electrical Projects - LOTS of thumbnail picture links

Minor updates and edits above, just in case you are following some of my WIP projects.

 

Re: My DIY Electrical Projects - LOTS of thumbnail picture links

Great to see someone documenting the small details. Did a similar tidy up on my project. It is worthwhile simplifying and renewing harness connectors. Even if its old, it can be made reliable. Evan more so than some of the high tech, cheaply made current models.

 

Added pictures of my test fitting and lighting of some of my cluster LED lights.

This is not an original project, but most of the posts no longer have photos. Sad

I'll provide more pictures and details as I go along.

So far the testing went well, and I think my choice of speedo/tac lights will be a good one.

----

Red was a good color for the cluster - I added a seperate post to help people trying to do this

I also added a seperate post for my semi custom fork mounted aux lights
http://xjbikes.com/Forums/viewtopic/t=28766.html