Topic: New to the 750, need some help from the guru (PIC HEAVY)

[vtwin51]

Alright so on to tearing into things today.

It started with me staring at my bike for about 35min not exactly sure where to go.

I finally mustered the courage to start cutting(well testing first), then cutting. I started with the front turn signals that didn't work. I pulled them off and found the other side of the lead wires, tested for continuity, and cut. This bike is completely wired up for full functions, so there is a ton of wires going everywhere.

I found this wire going under the gear lever and it runs all the way up to where the speedometer is. It wasn't connected and I tested it, then cut it out. I believe(hope) this was the neutral indicator.

I have about 10 different wires going to the headlight/horn/turn signals control. I would like to get all unnecessary wires out of here as well. All I should need is a switch with 2 wires for my head light. I'm thinking of fabricating something to the headlight housing itself. 

I also found "something" that might be the the problem all along. I was pulling around on the wires and was looking at the 15A fuse and its connections. Well it wasn't blown. but as I wiggled it I noticed the bridge wire was moving excessively. I pulled it and out half of it comes.

I'll be so pissed and happy if this was the culprit all along. I put the piece back in and kicked the bike to life. It ran just fine so I started wiggling the fuse again and it kinda started sputtering and sparking on the fuse then it died. At this point I'm not sure what to think. I hope this is it but I feel like there should be other things wrong with it.

So I replaced it with this solid fuse holder that's all protected now. Shouldn't have that happening again.

I'm going to continue with the minimalist wire job and will still relocate all the wires outside the starter box. The only issue I see with this is I'm doing multiple changes without full tests after each move to figure out what the issue was.

thoughts?

[vtwin51]

the new fuse holder.

[vtwin51]

So today I got into it again. I cut the hell out of those wires. Even one I wasn't supposed too, Damnit. But after about 3 hours I had it all back together and did a temporary fix for the wire housing and regulator/rectifier. I used an old M16 magazine pouch I had laying around and got all the wires and capacitor into it and cut a little hole for the ignition switch. It mounted up pretty sweet. Again it looks temporary with all the zip ties but I wasn't set on this idea.

So after I get it all together I get all excited for its first kick and maiden ride sense I chopped the wires. Annnnnd...... NOTHING!!!! IT wouldn't kick to save my life. No spark for sure. So I pull everything apart again and test everything. WTF. Alright so Nothing is disconnected or missing... What could it be? Then I remember reading around in the forums about some REG/REC needing to be grounded, usually through one of the bolts its connected with the frame. So I ghetto rig an exposed wire the REG/REC and ground to frame.

First kick and she's running good!!!!

So now I get to fashion up a good solid ground bolt and hook it to the frame tomorrow. Then maybe I'll get to ride her and find out if I fixed the issue. And a half hour later I get a package in the mail must be my lucky day. I'd like to have the best running carbs. lol not sure if thats possible with velocity stacks.

Let me know what you guys think of the wire housing.

[kpier883]

I hope you found the problem!  Cool bike.

[vtwin51]

Today I got that ground wire affixed to the REG/REC. Turned out pretty clean. I feel like I'm starting to get the hand of DIY things with the bike.

I also changed out the old fuel lines. Let me know if you guys think there will be any issue with their position.

I also had an idea awhile back to make a tool bag out of some old Army stuff. So I used another one of those magazine pounches and bolted it to the back of my license plate bracket. It worked out perfectly. Real clean fit. I then used an old weapon cleaning kit to hold the tools.

And after gutting most the wires I dont really want to keep the old turn signal/horn/hi beams switch so I got a new small one that I'm still deciding on where to place.

[Stev-o]

Why'd you put fuel filters on? Those have been known to cause issues. I'd take them off last least til you get this sorted

[vtwin51]

I've always had fuel filters on. I got new lines and new filters and put them. The old filters started showing small flecks of something from the tank (rust, Paint, debris)?

Any who, I finally got around to messing with the carb sync kit. It seemed to be running pretty good before I messed with it and I definitely messed it up at first but now it running pretty smooth. I thought at first I was looking for a specific number to reach for vacuum but then realized I'm just trying to sync the carbs to a reasonable idle. BTW That's real irritating without a tach. I've considered adding one just for this reason.

I took the bike out for a ride after and all seems good. Only got in about 20 min of riding but it ran fine. Blew a tail light for unknown reason. I'm thinking of going to a LED for tail light to try to keep from blowing the filament. This is the third tail light I've lost in 2 months. Obviously something is messed up.

Also to add.

The REG/REC was barely warm now compared to before. I couldn't touch it when it was attached to motor. And all the electronics aren't hot either.

[excellrec]

Hopefully that fixed your problem.  I also had issues with filament taillights on my 750 and had to switch to led after getting two tail light tickets (one 24 hrs after putting a new bulb in  ).  I should add, however, that I got pulled over again(!) with my led taillight because it did not have a reflector in the housing.  So, don't make the same mistake I did!

[vtwin51]

Today I took her out for a good 1.5 hour long ride. Rode like a champ. No issues with her running. So I think its fixed. I'll chalk the problem up to electrical over heating and the fuse gone bad too. Now with the REG/REC it barely produces any heat and everything is running good.

But naturally as I pulled up to the house my front brake started squeaking. Yay for a forever project. I've learned a lot about this bike with just this issue.

Thanks everyone for you help and input. It really is a great help having the extra opinions and ideas.

[EnvinoVeritas]

so glad you got her going!