Exup1000.co.uk :: View topic - Vivian

banner001 · Pit-lane Reporter

headlight clamps are here, theres no mounting point for the indicators (yet), so its washers and friction holding them on at the moment...but they look good, good enough for the next year at least (before the radial front end gets fitted)

ive knocked up a bracket for the horn (will NOT be the final solution) so that turns with the forks as well, now im just waiting on acewell to deliver me my clocks, then i can wire in the electronic speedo pickup, new water temp sender, and air temperature sender, and i can make my front loom!

here's the view all the people in front will get (minus clocks)

creedxup · Parts department

Looks good from the front. smile

The height of the coolant in the head is approx 5mm below the joint between the head and the cam case.
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1992 RU midnight blue, Wiseco 1070, 6 speed, r1 calipers, ducati discs , 157 bhp crank, Ohlins shock

banner001 · Pit-lane Reporter

cheers chris, ill have to get my tape measure out, i dont think im gonna have a lot of room for a "standard" ram-air, also ill need to look at positioning the horn someplace else, or go with a slightly "serpentine" intake from under the forks, over the radiator then under the frame and into the airbox.

until i get the front forks replaced, and get the custom yokes built im not thinking about airboxes...but its a constant thing i have to consider...the bike has to be able to breath better than the current system.

a friend of mine in japan thinks he can potentially pick up FCR39/41's for ~£450 shipped to the UK, once i get the money saved up ill give him a shout, might even be able to just get away with running pods?

but flatslides and a well designed air intake, maybe with some re-profiled cams (i'll email kent at some point) would be some nice power gains big grin

Gord · Test Rider

I changed my YZF 750 choke lever for a Thundercat choke lever, it's all part of the left hand switch gear. It makes it look a lot neater than the standard set up.

banner001 · Pit-lane Reporter

cant find any decent thundercat switchgears, but there is a decent looking thunderace one (also with choke lever) on ebay, ive stuck a bid on it, would be nice to bring the choke up onto the handlebar.

im currently buying a proper wire striper, crimper, and a load of wiring from here
http://www.vehicle-wiring-products.eu/VWP-onlinestore/home/homepage.php

ive emailed acewell to see when the clocks will be here...front end is starting to come together big grin

ill be fitting a thunderace or R1 throttle at some point too as i think it looks smarter than the current one.

ive been pulling out wires (ive also noted that the "UK" wiring in the service manual is not what my bike has, mine is more like the wiring in the haynes manual), so i have an oil light relay in there.

so far ive removed the 2 unnecessary (green/white and yellow/red) wires from the original indicator relay and ive fitted my new LED relay (tested with all 4 indicators and looks fine). im currently in the process of removing the clutch and sidestand lockout switches fully:-

i think ive got it right, i need to connect the black/yellow and blue/yellow wires from the relay to ground (black wire), and i need to connect the blue/yellow wire from the CDi to ground as well...ill test it tonight, if its ok im going to shorten the wires so they are as short and compact as possible.

ive also wired the reserve switch permanently on and removed the wires for the resistor and the fuel sender as these are now redundant (and ill be fitting a proper fuel gauge).

then if thats ok ill look at removing the oil light relay (it does nothing as far as i can tell) and that should be ok for the moment. i dont think there will be any more wires to remove.
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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

found this for the fuel tank...might be able to get away with this and a rubber/cork seal for the underside of the fuel tank...ill measure it tonight.

https://www.merlinmotorsport.co.uk/p/vdo-steel-weld-on-flange-for-dip-tube-fuel-senders-2-250-264-1241
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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

been tinkering...

ive "dry" tested it, and im pretty sure if i get stick coils fitted, i should be able to relocate almost all the electrics to under the front. ill cut a replacement bit of plastic and fit "fingers" to it to allow me to hold the various components in place.

ill make it longer so it fits over the engine completely and keeps the heat out, and ill probably shield the carbs with some reflective matting to keep the heat down...i might get hold of a temperature datalogger and test it on my zxr to see how much heat resides under the airbox...i think it will be fine, it might get up into the 40C's or 50C's...but it will be fine.

the pink/green sponge is the same size as the fusebox so i could gauge it.
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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

my

clocks

arrive

tomorrow

, and the rest of my wiring/fusebox/crimp connectors/battery crimper etc will be middle/end of next week...i know what ill be doing for the next month
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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

now i have a mass of wires:

and a sweet clock... big grin

now to get on with buying the last of the wiring and start the full re-wire big grin

_________________
Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

£150 of wiring and connectors bought should be here in a few days time...here goes nothing big grin

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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

The rewire is underway big grin

_________________
Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

been cutting the wires for all the relays/cdi/fusebox etc, and insulating as necessary. doing it this way i can ensure that the only "old" bits are the physical boxes themselfs. ive manages to make a plastic template from the old temperature shield (what the coils attach to) and ive worked out where to attach my boxes, the airbox still fits, and there should be space inbetween the oil relay and CDi, and inbetween the CDi and relay junction box to fit most of my bikes wiring, or it will go down the edge of the frame and oil relay/junction box...ill be fitting stick coils and should have loads of room.

im making up my lengths of wire fairly precisely (within 2mm) so that i get a calculated bend (look at the CDi for instance) and my wires are not gonna be under tension/compression - should increase their life.

im doing the bits that dont require me to do much work first, so things like the pickup coil, spark plugs, fuel pump etc, i need to get my clocks onto a bit of a homemade bracket next (ill measure it and CAD draw it tomorrow) so i can work out how to wire them up into my new loom, ive semi-sorted out where i want my wires to "spur" from, its just a case of packing them all in now big grin

i should have enough room, im not able to measure it exactly, but it looks like there should be plenty of space, it should also make removing the loom easier as it will be very thin where it snakes under the carbs and inbetween the seat and the frame/engine.

more tomorrow big grin

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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

nuggitt · Moderator

Very artistic John. thumbsup

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Bit of advice. Buy a good bed and a good pair of shoes, because if you aren't in one you'll be in the other.

banner001 · Pit-lane Reporter

did a quick cad mockup of a possible clock mount:

looks ok when its mounted with the clock, but it will need modifying, and its mounted too far from the yokes at the moment:

from the front:

modified some of the mounting points a bit and moved the fusebox, checked with the airbox it all still fits...so all good so far

this was earlier in the day, ive been wiring like a demon today, ill be off out again in a bit, want to wire a few more connectors, im almost at the point where i need to start wiring the lights and indicator bulbs...that kind of thing, so im making headway.

no guarantees that it will all be good yet, but im pretty hopeful big grin

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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles

banner001 · Pit-lane Reporter

situation as of last night, gonna start wiring in the switches and lights soon, last will be the clock power/tachometer/fuel sender/battery and the exup servo (needs extending to the back of the bike):

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Current bikes:
1989 UK FZR 1000 EXUP-R Streetfighter @48,000 miles
1993 ZXR 400 L3 UK-spec Track-bike @21,000 miles
1994 ZXR 400 L4 UK-spec Commuter @48,000 miles
1999 Malaguti Phantom F12 scooter with 70cc kit+mods @14,000 miles