Series 1 update - Custom wiring loom for rewired casatronic.

[davet]

I wanted a specific wiring loom to fit with the rewired casatronic/wassall set up. I'd already been running twin horns, spot light, fuel gauge, phone charger and rev counter on my existing set up with full DC lights.  But I had wires, fuses and relays all over the place.  So after doing some bespoke wiring jobs for a few  mates, I wanted to have my own set up.

I shared some ideas with electric guru Pugwash and set about it.  It took a while with some nice coloured pens to design the loom and after the big wiring products box arrived I was away with another picture story.  I've got to say at this point I'm not advocating this is the right way, just my way.  Some may think it's a bit ponsy, but it works.

Loom shaping up.  Note pretty wiring diagram.

Wiring loom completed, I fitted it to the scooter with everything ending up where the original butty box is located.  I use a diablo tank with a cut out for a battery.  I needed a way of fitting the fuses and relays in one place and came up with a cantilever approach which seemed to work.  I also wanted to put the ignition and a voltage indicator in the same area.

I used some high density foam to dampen any vibes and to protect the holder from hitting the tool box door.  I'm using a Vespa ignition switch, which should piss off a few people.  Result.

All wires connected, showing underneath fuse and relay holder.  Clear copper wire is for a good earth.

[davet]

Next to sort other side and show what's happening up at the headset and in the butty box.

[bikegrim]

Mine next big man. Can't believe you haven't credited me for the toolbox lid idea. Hahahah

I am also a "user" of one of Davet's magical DC (using Wassel and Ducati type stator) wiring looms but am eagerly awaiting his offer to do ( not having the patience myself) do a varitronic DC conversion.

[pugwash]

Oct 28, 2016 7:52:42 GMT bikegrim said:

Mine next big man. Can't believe you haven't credited me for the toolbox lid idea. Hahahah

I am also a "user" of one of Davet's magical DC (using Wassel and Ducati type stator) wiring looms but am eagerly awaiting his offer to do ( not having the patience myself) do a varitronic DC conversion.

 Dave never told me that it was your idea "Unbelivable" I credited him with the bifold toolbox door idea.

 Works very on mine too thanks "Dave" for the great idea that you stole   hahaha !!!

[davet]

Gareth, you've cut to the final reveal credits. Like every good film, they were going to roll at the end. From now on you'll be known as Mr. Cantilever

[bikegrim]

Oh bollox, I feel like I've found my Christmas presents before they've been wrapped. My sincere apologies Dave
To be fair that is far more developed than the idea of just sticking it all to the inside of the door. Very well done as usual

[GeorgeS]

What are you using for a stator? I'm putting together a grand turismo 240cc but really don't know which way to turn on the electrics front.

Anthony Tambs has a nice external pickup solution coming soon but this is DC only and I was planning a sip speedo which needs AC for rev counter (could switch to one of his gamma tech things I guess).

Bgm looks good with easy spares but hearing a lot of reliability issues on those at the moment.

[bikegrim]

I'm using a converted Indian stator with a wassel. You can run your SIP rev counter off one off the yellows from the wassel. Davet and Pugwash are us using DC converted varitronic stators

* edit: I'm using a BGM DC stator and have been for almost 8000 miles with no issue. The AF Indian stator that Davet converted to DC is in my spares bag unused.

[GeorgeS]

Thanks for the info, & apologies for hijacking the thread somewhat.

BGM Stators seems a funny one, you'll get people like yourself who have had no bother at all and then others who say they last 5 minutes. I guess you need to keep in mind that those with problems often have the loudest voices & there's no catering for the stupidity of some people's installation methods.

Anyway, I'll be following your progress with interest as I plan to make my own loom for my series 2, so please do post up more info.

[bikegrim]

I have had an issue with a BGM AC stator that basically went intermittent on me and meant that I didn't complete the C2C but that was back in April 2015. We tested it on and off the bike and it's reading were fine. But it would still break down. Since then I have run the same setup as described above with no hassle. Fingers crossed.

I want to go on to varitronic to get the best out of my motor but don't want to lose the benefits of DC.

[pugwash]

Oct 28, 2016 12:44:37 GMT bikegrim said:

I have had an issue with a BGM AC stator that basically went intermittent on me and meant that I didn't complete the C2C but that was back in April 2015. We tested it on and off the bike and it's reading were fine. But it would still break down. Since then I have run the same setup as described above with no hassle. Fingers crossed.

I want to go on to varitronic to get the best out of my motor but don't want to lose the benefits of DC.

Get Dave on myself to convert a Casatronic or Variatronic stator to run full dc, all you might need to change is your rev counter.

It's not a big job, only takes a couple of hours.

[bikegrim]

Pugwash it's for the S1. Got it here and a beedies loom ready to connect up. Will need loom, battery and relays etc for DC. Keeping the existing DC set up on the S2.

[davet]

Next step was to tidy up the wiring coming from the Daytona speedo/tacho and fuel gauge. I wanted to get more room inside the butty box, so changed both to surface mounting and clean up all connections. I decided to use another Series 1 junction box under the existing one under the horn/headlight cover. Thus meaning I could have wires straight through the butty box with all connecting cleanly (sort of) in one place. I just had to weld another bracket to the fork tube.


Top is usual coloured wires. Bottom is where fuel gauge, spot light and speedo/tacho join up to main loom wires. The round connector is where all of the earths meet up.

I converted the headlight to an H4 bulb at the same time giving me some options on bulb colour and power. I'm currently using a 45, which is bright enough.


No connectors in butty box now. I used some high impact foam to protect the spotlight wires where they come out of the bolt.



Everything finished. I also changed the battery to one of those super light lithium ones. Basically the electrics are now controlled by a main relay, which when switched on powers everything up. The other two are for the spotlight and horns. Fuses are for main, speedo, fuel gauge, usb charger, horns and spotlight, with three spare.

[davet]

Cocked up with the last photos, here's the spotlight and finished holder.

[davet]

Here's a video of the GICS (Gareth inspired cantilever system) in use. I also fitted some micro switches to control the speedo/tacho.  The voltage gauge is upside down so I can see it when I'm riding.

[bikegrim]

Slick. What have you got in the headset where the ignition used to be?

[Mel]

Oct 28, 2016 8:07:44 GMT pugwash said:

Oct 28, 2016 7:52:42 GMT bikegrim said:

Mine next big man. Can't believe you haven't credited me for the toolbox lid idea. Hahahah

I am also a "user" of one of Davet's magical DC (using Wassel and Ducati type stator) wiring looms but am eagerly awaiting his offer to do ( not having the patience myself) do a varitronic DC conversion.

 Dave never told me that it was your idea "Unbelivable" I credited him with the bifold toolbox door idea.

 Works very on mine too thanks "Dave" for the great idea that you stole   hahaha !!!

He'd have got away with it too if it wasn't for those pesky kids .

[davet]

Still have the original cut out, but disconnected. I relocated the ignition from a hole in the top of the butty box.