Bushyboy's build thread

I guess those of us with the 70-71 carbs should consider ourselves lucky.
These can be easily rotated in place to gain access to the bowls and tops.

I am about at my at my wits end here. I have been having electrical gremlins. First my headlight and taillight weren’t operating. Figured out the headlight was that a connector on fuse panel needed replaced and repaired it. Started troubleshooting taillight when now I get a drop in voltage when I turn the ignition switch on. Hours spent troubleshooting so moved on to taillight. Problem there was cheap Chinese eBay taillight solder joints broke. I have unplugged everything and checked multiple wires. I once unplugged the rectifier and everything was normal again. But then moving back to taillight I hit hand brakes and problem came back with rectifier unplugged. Removed whole headlight bucket and wire harness from headlight bucket. Checked ignition switch and cleaned contacts inside where I was sure was the issue. I got it to duplicate the problem in the switch. I had the switch on reading 12 volts and started working. While one and reading 12v squeezed brake back to problem. Tried to wiggle ignition switch harness contractors and get switch to operate again no luck. Battery reads 12v in off but draws down voltage in on. Some other things I thought were the problem but turned out not to be. I turned the run switch to off and the voltage on dropped to 5v when I turned on ignition. I have unplugged hand brake, run switch, everything in headlight bucket except ignition switch still causes and issue. I am going to unplugged all harness in the rear again after I eat. Any one ever experience this electrical phenomenon? Is it just the switch and I’m about to set fire to the bike for no reason?

This really is weird it works randomly and then seems if it gets a load it will maybe work a couple times and then stops working again. I just got a brand new battery last week and it has been working fine. I just kinda encountered this checking my fricking taillight. I think I should put it all back together like it was and then start it and see if it does the same running.

Certainly sounds like a gremlin or two.
I got nuttin'.
Hang in there, keep rattlin' at it, they can't outlast you...

Only good news today is I was able to combine the old taillight with the after market license plate holder and get it to function as it should. Still can not figure out my issue with the electrical.

So digging through the forum I have read of a few similar issues with AGM batteries. I just replaced my el cheapo that was only putting out 60 CCA for a new AGM about a week ago. I guess I am going to head done to the parts store and have them check this one. If they determine it to be bad I may just spend a few more bucks and wait for them to deliver a lithium battery.

Well I’ll be GD’ it was the battery. Found out after pulling out my hair and about pushing the bike off a cliff. Oh well at least I upgraded to a lithium battery.

Repainted my exhaust after it fell off doing runs adjusting my carburetor. It needed a repaint anyhow so not really a loss. Can anyone recommend a clamp for the MAC 2-1? It doesn’t look like there is much space in between. I was thinking about springs to hold the muffler onto the pipes. Also what exhaust gaskets are you using to seal the pipes? The last ones I got were kinda shotty.

Well found some t-clamps at tractor supply and some copper gasket sealant at advance auto. I was able to slide on the t-clamps on both pipes and tension them down on the muffler. I smeared the copper gasket sealant on the pipes that connected to muffler and the gaskets exhaust side. Doesn’t seem to be leaking, but time will tell.

A few current shots of the XS.

I swear I’m about to get a PMA on this thing. Charging issues once again; 13.5ish volts between 2000-3000 rpm with headlight unhooked. I know I’m just venting my frustrations and will probably just fix the under lying issue with my charging system once again. It has to be better then forking over $600.

So I don’t know if the neutral switch wire has anything to do with the charging system. I had to check three different schematics before I even found what the sky blue wire was. The terminal is not locked in the connector so it may have been intermittently connected. I plugged it up as tight as I could get it for now and the charging system is now operating as advertised.

Bushyeyed1 said:

So I don’t know if the neutral switch wire has anything to do with the charging system.

Click to expand...

Nope. All the switch does is provide a ground for the neutral light.... when in neutral.

Received a set of TEC piggybacks. And before anyone judges them saying they are cheap Chinese pieces of crap I did some research. While they may not be ohlins they are really good quality material from what I can tell. They are about twice the price of the Chinese piggybacks but still affordable at $176 shipped. The manufacturers are actually located in England so the instructions are in the common tongue. I watched a video of someone I follow on YouTube and he actually visited the plant where they make the shocks. They have become popular on motorcycles here in the states they now have a distribution center in the US. So that being said I will let you know how these shocks actually hold up with my build.

So as some of you know I am getting my bike ready to pass Hawaii laws. I didn't want to rewire my led turn signal set up so I improvised and over came. I shortened the stalks on the stock turn signals and added LED bulbs inside. Hopefully the words DOT on the turn signals will fool them that LEDs are actually installed.

I got my mid set controls from oldschoolspeed on my bike and took her for a spin. I love the comfort of the seating position now with my handle bars. The controls are made very sturdy and excellent quality. I was able to adjust the brake pedal and foot peg so the kick start lever clears the controls with the peg in the upright position. I did have to cut a small bit off the kickstand lever so I could use the clutch lever.

Got the slotted disc for the front installed. Not sure if it will work any better, but it is definitely lighter then oem.

Not sure if my build is calendar worthy yet, but got a few good pics today. These are my favorites anyways. I had a nice long ride just trying to burn off the gas in the tank prior to the movers picking it up next week. Hopefully soon to follow will be pics of her in Hawaii.

Been a minute since I’ve posted, but you can bet I’ve been missing my baby. Next Friday we will reunite and maybe I can sneak her off without my wife noticing. Anyhow I hope she made it in one piece and as promised I will get you folks some pics of her in a bikini on the beach. Enjoy the sunset on the north shore.

First picture in Hawaii I’m sure it’s not what you all expected to see but hey at least it looks better then some of the furniture my wife is crying over. After we unpack all the boxes I plan on getting her some gas and blowing the dust off.