re-wiring my bike

4854 Views 10 Replies 6 Participants Last post by exploring/carolina, Dec 4, 2010

jreidfive

Discussion Starter · Nov 30, 2010

I posted this in the tech help forum before i even realized there was a forum for custom/mod topics, i think it probably belongs here instead...(pasting the text)

okay, first off, since i still haven't changed my signature, i have an '81 cx500C...now, down to business. i'm turning this bike into a custom something or other (most likely café racer) and i want to dramatically reduce the stuff on this bike, including the wiring. what i want to do is dump the ignition switch and key, and use a switch with push start set-up, that is, have a switch that turns on all systems and doubles as a kill switch, with a push button start to activate the ignition process. i'd like to keep brake lights and turn signals, and i can go either way on the high beam, though it'd be nice to have, just in case i want to take my handy to spotlight for deer in the field. i just finished browsing all 14 pages of the tech forum and have seen some useful info in the form of wiring diagrams (which i've downloaded and will definitely use), but what i'm looking for now is any advice from anyone who has done this in the past. i mean, i am fully prepared to spend a few days and brain cells tracing wires and trial-and-error testing, but if there's anyone who knows what's up already i'd appreciate the info. is it even possible to do this with the cdi/stator system? i'm not an expert on bike wiring, so anything i do at this point is pretty much shooting in the dark. any ideas? i guess my main area of concern is condensing everything the ignition switch does into a single on/off switch...but given my limited knowledge in this area, i may well be vastly understating the challenge ahead.

thanks!!

~J

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exploring/carolina

· #10 · Dec 4, 2010

j_reid said:
I was thinking about the battery relocation...i was originally planning a monoshock conversion, hence the battery problem, but figured i'd have to switch to a sealed battery, turned sideways, mounted under the engine to pull it off. i've since moved away from the monoshock idea (for now) but i'm still deliberating the battery move. the cx definitely looks better either completely open in that area or with the side covers on, and with pod filters i wouldn't want the side covers there anyway. i'm still planning, i'd like to do something other than standard cafe racer as well, but right now i'm still taking apart and scrubbing down all the pieces, so i've got some time still to think about it. and regarding the wiring harness, what i really wanted to do was just get rid of the ignition switch and condense everything into one switch and push-button set-up. to make it easier for the bike thieves out there.

Installed pod air filters and a battery/regulator tray in the following photos. Used 6061T6 .040" sheetmetal and angle for most of the installation except for 1/8"X1" steel straps for original battery bracket installation and .040" side covers.

Working on the wiring at this time with the ignitech ignition: