Since last time:
- Throttle is mounted. I needed to cut the switch/cable holder on the bike to make space for the Magura's resistor/rehostat/whatever its called.
- Main power switch is mounted on the left frame side. The switch is huge and round, I ended up purchasing a 1 3/4" hole saw to seat it in the frame. My rechargeable 6 volt drill actually was able to drive the bit to make the hole. Much hacking and chopping was required, as the aluminum frame member had a cross piece within that needed some attention. The fit is perfect though, it looks really good.
- Fuse holder is installed on the rail near the switch. Like the switch it is sheltered within
the thick frame. I intend to cover the top, perhaps the bottom too with plexiglass to prevent any fingers getting inside.
- The big solenoid/relay is in place, mounted to the rear of the battery cage, re-using a bolt (got to save weight somehow!). When the DC-DC converter is working, I want the ignition key and motor stop/start switch on to activate/deactivate this relay, which will then power/depower the controller (and hence motor/wheels).
- Motor mount. Bob's Machine shop came through, delivered a pricey but well executed piece. I needed to hack it down a touch to account for weld thickness at the base of the original motor mounts. Once cut and confirmed to fit, I spray painted the plate and the other mild-steel cross member flat black to prevent rust - the result looks great. I added a 1" chunk of tube to the cross member to support the plate rather than using some L-brackets I purchased for added support.
- With the motor mount in place, I mounted the motor as per the El Ninja instructions - 4 x 3/4 x 5/16" bolts.
- The small front sprocket got put on next. I need to apply threadlock/etc, but I want to test alignment/get it moving first.
- The chain tool did great pushing out links, but not for putting them back! So I ended up using a master link, a no-no in the ZX-11 manual. 130 hp vs 15, I'll risk it. The chain is also touching the top of the swing arm near the engine compartment - an inch or 2 higher on the mount
would be a good idea. The center kickstand is hitting the chain from the bottom when it is up. Rotating the axle holders to move the axle up has helped, but its not right yet.
- The rear sprocket got reveresed - the inset is now faing the hub to bring the big ring slightly closer to the wheel and to better line up with the small sprocket up front.
- DC-DC converter. Installed in the battery box. Added a fuse holder too, but discovered its only rated for 36 volts and below (?). I am debugging the electrical, looking for a clean 12 volts but have only blown fuses so far. Its a 3 wire system.
- Wiring. I bought a propane torch for melting solder for the big lugs and think wire. I have 14 Gauge wires going from each battery pair to a "stud panel" where I am going to run the chargers too. This should allow the chargers to be removable as a unit with unscrewing some terminals. Perhaps I can find some nice plugs...PC power cables might be the ticket.
- Mounting wires to the battery terminals has been educational. Its a big detail I failed to put much thought into, but the lugs with wires and bolts are really bulky. I padded the 2 batteries I have in tight using thick cardboard, because any motion threatens to short out some terminals accoss the frame somewhere.
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