Sunday, 4 May 2014

GPZ 1100 Custom Wiring - Part 1

Mercenary Garage - GPZ 1100 Custom Wiring

It's pretty busy in the workshop at the moment - I'm drowning in dissembled motorcycles. The Buell is in bits for powder-coating and wrapping. Noel's mini-moto is also waiting for some powder-coated parts. The Africa Twin is just sitting there forlornly until I can afford new wheels. The Ducati Superlight is hanging around like an evil ex-girlfriend and there's an RD200 motor on the bench waiting for inspiration (and money).

In addition to this I took on a wiring job for another GPZ1100 that needs to be finished before Wednesday so yesterday was a workshop day.

I really enjoy wiring. It's like a cross between painting a watercolour and doing a jigsaw and it requires a lot of flow-state thinking. Time passes very quickly in a flow-state and consequently, I'm surprised at the amount of time it takes. In my memory, a wiring loom only takes a couple of hours, but what you see here is a solid eight hours of work.

It's going to take another day to finish it which shouldn't be a surprise 'cos the last loom I did (which was coincidentally also a GPZ1100) took about two days - www.mercenary.ie/2013/05/evans-gpz-wiring.html


Mercenary Garage - GPZ 1100 Custom Wiring
Getting organised!


Mercenary Garage - GPZ 1100 Custom Wiring
Looking at this image it might be hard to believe that this loom came from a running motorcycle, but I've seen looms in much worse condition than this!


Mercenary Garage - GPZ 1100 Custom Wiring
This is some bad juju! I don't know what that white cable is for, but the other end of it is soldered to the fuse in the previous image.


Mercenary Garage - GPZ 1100 Custom Wiring
The last GPZ I wired ran on pod filters rather than an airbox so I had a ton of room to put electrical stuff. This bike is retaining its airbox so space is tight. I need to make a mounting plate for the fusebox and relays.


Mercenary Garage - GPZ 1100 Custom Wiring
The mounting plate more or less finished. I can't give it the time to polish it or paint it but its not going to be visible so this will have to do!


Mercenary Garage - GPZ 1100 Custom Wiring
Mounting plate with fusebox and Hi/Lo beam relay. There's another relay on the far side of the mounting plate. I always run headlights through a relay. It reduces the risk of melted wiring and also gives a brighter, more reliable headlight. Normally I run the horn through a relay too, but in this case I don't have room for another relay.


Mercenary Garage - GPZ 1100 Custom Wiring
Everything in it's place... By the time the wiring goes in, this'll be pretty tight!


Mercenary Garage - GPZ 1100 Custom Wiring
The main earth cable goes from the negative terminal of the battery to the engine casing to accommodate the heavy current from the starter motor. This is a frame earth that connects the frame to the negative terminal. I'm tapping a spare M6 bolt-hole to remove paint and corrosion to ensure a good electrical contact.



Mercenary Garage - GPZ 1100 Custom Wiring
I'm happy with my day's work!





Part 2 is here... www.mercenary.ie/2014/05/gpz-1100-custom-wiring-ii.html
Part 3 is here... www.mercenary.ie/2014/05/gpz-1100-custom-wiring-part-3.html
Part 4 is here... www.mercenary.ie/2014/05/gpz-1100-custom-wiring-part-4-end.html


#CustomMotorcycleWiring #GPZ1100 #Mercenary #MercenaryGarage

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