-----Original Message-----
From: Trevor Hughes <Cb1100rtrev@aol.com>
To: Vincent Crabtree <V.P.Crabtree@lboro.ac.uk>
Date: Wednesday, 29 January 2003 23:44
Subject: Re: Small Honda singles.

Vincent

 

Sorry I have been so long getting back to you but I hope this makes things a little clearer.

 

I have looked at your page again and have a few more coments!

 

Predator exhaust systems can be found at WWW.predatormotorsport.co.uk  as you have mentioned the build quality is good and they are very rugged, but in my opinion the exhaust is a little long and the silencer looks big on the XL185 frame.  Mine has been slightly modified (shortened by 55mm) and the appearance is something you get used to.

 

My 12volt conversion is not adding extra windings.

 

The XL185 has 3 coils in the generator ignition, headlight and battery charging.

 

1/ The small battery charge coil is desoldered from its 2 wires and removed.

2/ The larger headlight coil is then disconnected from the earth and the White wire, these coil connection are then soldered to the Yellow and Pink wires formerly used for the batter charge coil and insulated using epoxy.

3/ The White wire can be cut out but must be left though the grommit to stop oil leaking.

4/ This now allows for the output from the former head light coil to be connected to the XL185 rectifier (hence full wave rectification).

5/ The full wave rectifier output is then connected across a 12volt Zener diode fitted to a heatsink. (hence very good 12volt control).

6/ This output is also connected across a big capicitor for smoothing (I used a car condencer).

 

You now have a very smooth 12volt signal which can be used for all lighting and charging.  It must be remembered that the output is limited and I wanted to run without a battery so my bike has the minimal amount of lighting.

 

35/35 watt headlight

5/21 watt tail/break lamp

2 watt speedo light

5 watt route card illimination

5 watt neutral light

Horn

 

I did find that the headlight would dim when the break light was activated so I have now installed a small battery which will charge from the 12volt but only operates the break light.  This battery is only installed for night time events and I see no reason why a bigger battery could not be used and then even indicators may be a posibility. 

 

Please picture below for wiring digram.

 

 

My bike was built by myself in 1995 and has proved very reliable, it was built for long distance trial's so this system may not suit all other application's.  The system uses a loom made with as few connections as possible, all uneccassary items removed and a common earth wire runs thoughout the loom so as not to rely on frame connections.  All connectors are good quality and cables are over rated so as to help reliability. All cables, components and connectors supplied by:

 

Vehicle Wiring Products

9 Buxton Court

Manners Industrial Estate

ILKESTON

Derbyshire

DE7 8EF

Tel 0115 9305454

E-mail: sales@vehicleproducts.co.uk

 

for free catalogue. 

 

 

Regards

 

Trev