FrankS 1978 Special

[jaybar6]

Still waiting for a carb floats, and then I have to mess with the points with mangled screws. Need a new clutch cover gasket because this one broke at the very bottom where it's needed the most.

Tank and side covers with badges on. I like it.

View attachment 334672

Feeling pretty good about the electrics, I decided to plug in the headlight, turned the ignition key on, turned the headlight switch on, and bam! Fuse blows to red wire with yellow stripe. Greeaaat!

Hi frank, oh dear! the mystery continues. there a number of questions I would like to ask:

Before you hit the light switch, 1) did any of the lights light up on the binicale , the red brake light and the green neutral light?
2) did you try the indicators and did they work?
3) did you press the horn to see if that works?
4) did you squeeze the front and rear brake to see if that works?
5) is there 12volts on the points?

 

[Kevin Werner]

Watching, hopefully this short is found soon

10 amp fuses are going scarce?

 

[Kevin Werner]

Shorts are pretty easy to find. Replace the 10Amp fuse with a 50 amp fuse and see which wire melts.

 

[FrankS]

Hi frank, oh dear! the mystery continues. there a number of questions I would like to ask:

Before you hit the light switch, 1) did any of the lights light up on the binicale , the red brake light and the green neutral light?
2) did you try the indicators and did they work?
3) did you press the horn to see if that works?
4) did you squeeze the front and rear brake to see if that works?
5) is there 12volts on the points?

Done for today. Will respond when I get back to it. Thanks!

 

[gggGary]

Still waiting for a carb floats, and then I have to mess with the points with mangled screws. Need a new clutch cover gasket because this one broke at the very bottom where it's needed the most.

Tank and side covers with badges on. I like it.

View attachment 334672

Feeling pretty good about the electrics, I decided to plug in the headlight, turned the ignition key on, turned the headlight switch on, and bam! Fuse blows to red wire with yellow stripe. Greeaaat!

wires getting cut and grounding where they pass through the headlight shell is a thing.
Also solder blobs fall off the LH turn signal switch/wire connection, the feed wire can then short to the handlebar in there.
Other than thickness needed to maintain clutch push rod length the LH cover gasket doesn't really do much. Tears, holes don't matter.

 

[Adamc]

Adam, when you removed the reserve lighting unit, did you have to put in a jumper wire somewhere? Where?

Although others suggested to add the jumper, strangely I did not add a jumper wire and everything continued to work fine.
Later when I did the full rewire I eliminated all the 'safety' relays and cicuits to simplify the process.