A good and capable friend came over today & together we have spent today working on the Norge. Most of the work was on the wiring for the horns and adding an extra 40A fused feed from the alternator to the battery. We have also looked at some other bits and pieces of the loom and made some repairs.
We found a mysterious bridged connection up by the relays etc. by the battery compartment - we couldn't decide what it was for so just put it back into place:
We also found a relay with a damaged wire and a supply from the battery that had dropped off its connection & needed repairs. There's a yellow that was cut rather short and had detached itself from the bullet connector used to join to an in-line fuse & thence to the battery. On the other side of this connector is a relay. No idea what for.
Damage visible & yellow wire temporarily removed for repair:
Repaired & relay reinserted. I wonder what it's for:
Up at the pointy end I remounted the twin horns and reconnected them. Only one relay this time so only one supply cable, forked to both horns. We fitted the connection to the loom and the various power connections through a 10A fuse (there was an inline one but I don't like them so I've invested in a relay block with a fuse holder in it from VWP.) It took some messing about but now there's the original loom reaching back along the side of the air box and connecting to a twin cable to the relay and another cable running on the other side of the air box (heat shielded) and down the front of the engine to the horns as shown below:
There is a bit of a nest of wires in the battery compartment but actually there's less than there was. I now know what all the cables I have worked on do (I think) and after reattaching the battery the horns have been tested. They do the do nicely:
After that it seemed sensible to replace the air box and get that all sorted out. On went the air box and the daft little box on the front of the air box and after much wriggling and willing it all went into place and the connections onto the hoses were all reattached:
Then on went the hoses to the blow back box at the front:
I cleaned out the switch gear on both sides to try and get everything working better. The actions seem smoother so I hope all is good now. Then on went the front mudguard and the tank:
It is starting to look a little more like a motorcycle and less like a random collection of bits.
There wasn't anywhere near enough time to get the exhausts back on the bike. I am out all day tomorrow and so won't be working on it then. Sunday I may have a little headache and possibly a lie in. I still have leave to use and so I will be booking a week off late Nov and getting it all back together (I hope) then.
Irritatingly, I have realised as I write this up that the tank has to come back off as I put all the hoses for the little blow back box in place but didn't remember to tighten up the various fittings that hold the hoses on. Insert rude words here.
Nevertheless, all in all a good day's work.
We found a mysterious bridged connection up by the relays etc. by the battery compartment - we couldn't decide what it was for so just put it back into place:
We also found a relay with a damaged wire and a supply from the battery that had dropped off its connection & needed repairs. There's a yellow that was cut rather short and had detached itself from the bullet connector used to join to an in-line fuse & thence to the battery. On the other side of this connector is a relay. No idea what for.
Damage visible & yellow wire temporarily removed for repair:
Repaired & relay reinserted. I wonder what it's for:
Up at the pointy end I remounted the twin horns and reconnected them. Only one relay this time so only one supply cable, forked to both horns. We fitted the connection to the loom and the various power connections through a 10A fuse (there was an inline one but I don't like them so I've invested in a relay block with a fuse holder in it from VWP.) It took some messing about but now there's the original loom reaching back along the side of the air box and connecting to a twin cable to the relay and another cable running on the other side of the air box (heat shielded) and down the front of the engine to the horns as shown below:
There is a bit of a nest of wires in the battery compartment but actually there's less than there was. I now know what all the cables I have worked on do (I think) and after reattaching the battery the horns have been tested. They do the do nicely:
After that it seemed sensible to replace the air box and get that all sorted out. On went the air box and the daft little box on the front of the air box and after much wriggling and willing it all went into place and the connections onto the hoses were all reattached:
Then on went the hoses to the blow back box at the front:
I cleaned out the switch gear on both sides to try and get everything working better. The actions seem smoother so I hope all is good now. Then on went the front mudguard and the tank:
It is starting to look a little more like a motorcycle and less like a random collection of bits.
There wasn't anywhere near enough time to get the exhausts back on the bike. I am out all day tomorrow and so won't be working on it then. Sunday I may have a little headache and possibly a lie in. I still have leave to use and so I will be booking a week off late Nov and getting it all back together (I hope) then.
Irritatingly, I have realised as I write this up that the tank has to come back off as I put all the hoses for the little blow back box in place but didn't remember to tighten up the various fittings that hold the hoses on. Insert rude words here.
Nevertheless, all in all a good day's work.
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-- but I would swear under oath (with only mild worries about perjury 
), that I routinely get 200+ miles on a tank.
