Smallframe with a P200 engine?
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Ossessionato
1 Empty Garage Space, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4026
Location: San Diego, CA
Mon Apr 30, 2018 6:59 am quote
might as well spray bomb the plug you made

nice work.
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sun May 06, 2018 9:43 pm quote
I started on running the wire harness today. I decided use a Euro PX (with battery, with signals) harness. Iíd rather have used a US harness for the 2005 PX150, but itís not readily available.

Hereís a pic of the harness...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sun May 06, 2018 9:51 pm quote
Since Iím planning on running spot lights, grip heaters, and a GPS, I wanted to add more wires to the new harness before I installed it. To ďchaseĒ the wires though the sheathing on the harness, I used a leftover inner speedometer cable that I had laying around the shop. I canít remember what itís from, but it works amazing for chasing wires in auto wire harnesses.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sun May 06, 2018 9:57 pm quote
Hereís a pic of the speedo cable that I pushed through the wire harness. I started at the regulator, and it popped out up at the horncast. I soldered the end of my wire to the end of the speedo cable. After that, I pulled the cable the rest of the way through the harness. It was very easy. Took about 5 seconds.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sun May 06, 2018 10:01 pm quote
and an ďafterĒ pic of wire...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sun May 06, 2018 10:05 pm quote
And hereís a pic of the front. I ran two 16 gauge red wires starting from the battery area, to the horncast. One wire will be for the spot lights, and the other will be for the grip heaters and 12VDC power for accessories.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sun May 06, 2018 10:23 pm quote
Since this is a Largeframe harness going into a Smallframe, some of the wires will need to be shortened, while other wire will need to be lengthened some. I also added an additional ground wire in the harness as well. One can never be too well grounded.

I havenít shortened up any of the wires just yet because Iím waiting for a few more parts for my harness (turn signal switch, front brake switch, battery cable, ext...) to show up from Beedspeed.

Iíll also be converting over to a full 12VDC system as well...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:13 pm quote
Iím finally getting around to working on the PK. Iíve been waiting for parts to arrive from the UK, so Iíve been dead in the water for the past month or so. Because of that wait, I got motivated to do something with my stock sized fuel tank...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:19 pm quote
I used 18 gauge steel for the project.

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Last edited by whodatschrome on Sat Jun 16, 2018 11:12 pm; edited 1 time in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:20 pm quote
A couple other angles...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:24 pm quote
With the sides and bottom welding in...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:26 pm quote
I made the top out of 16 gauge.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:30 pm quote
Top all welded up...

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:33 pm quote
What it looks like from a different angle.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:35 pm quote
And the other side..

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Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7121
Location: Victoria, Australia
Sat Jun 16, 2018 9:37 pm quote
Wow! That's impressive.
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:42 pm quote
Iím thing it will hold an extra 1.5-2 quarts of fuel. And since the PK has a glovebox, I donít think the space that I lost will affect anything. The only thing I really ever carried in that box was oil. And since my plan is to fab up a custom oil reservoir for the auto lube, I wonít need to carry oil with me anyhow.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:48 pm quote
I also got a start on the wiring. I ended up mounting the battery underneath the fuel tank so I could have more room for ďotherĒ things under the cowl.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:51 pm quote
the regulator also got mounted under the tank, right above the upper shock mount.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 9:55 pm quote
I went crazy with the alligator clips while testing out some electronic devices.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Sat Jun 16, 2018 10:02 pm quote
I was hoping to be finished with the scooter by now, but the place in the UK where I ordered my headlight switches from, sent the wrong ones....and it took them a full month to get those wrong ones shipped. I returned them, they received them 6 days later. Now Iíve been waiting 2 weeks for them to ship out the correct switches that they have in stock. It looks like their super slow shipping, as well as their mix-ups is going to cost me close to 2-3 months of lost time!
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Thu Jun 28, 2018 10:40 pm quote
I got a fair amount accomplished on the PK in the past two days.

I was racking my brain trying to figure out an oil reservoir tank for the autolube. The main thing I was after was that I wanted something that I could glance at to see how full the reservoir is. So I needed something with a sight glass...then I thought of using a Nalgene bottle. From my google searching, it looks like the plastic wonít react with the 2 stroke oil.

I spent $8 on a Nalgene, drilled a hole in the bottom of it, then screwed in the fitting. I put oil in it overnight as a test, and no leaks were found.

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Last edited by whodatschrome on Fri Jun 29, 2018 5:45 am; edited 1 time in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Thu Jun 28, 2018 10:43 pm quote
A closer up pic of the fitting. The bottle mounts perfectly in a bicycle water bottle holder. You can also see the oil line going through the frame.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Thu Jun 28, 2018 10:46 pm quote
I also did a bunch of wiring. I mounted a fuse box (4 gang) right next to the bottle. Since Iíll have a few different electrical accessories, I want to get fuses on all of them.

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Last edited by whodatschrome on Fri Jun 29, 2018 5:44 am; edited 1 time in total
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Thu Jun 28, 2018 10:52 pm quote
Hereís a pic of whatís happening underneath the tank....

You can see the oil injection hose passing through the frame. I ended up moving my battery forward about another inch so that that hose could have room to slip past the battery tray.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Thu Jun 28, 2018 10:54 pm quote
...and the hose coming out though the other side.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Thu Jun 28, 2018 11:01 pm quote
Since I had to remove the battery tray again, I took a pic of it. The rubber strap is off of a KTM. KTM used that same rubber strap from about 1998 to present day. They use it as a battery strap as well a strap to retain the sidestand.

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Veni, Vidi, Posti
74 50s x3 78 P200 84 Cosa 58 AllState 68 Sprint 80 50special + projects
Joined: 22 Nov 2010
Posts: 7404
Location: seattle/athens
Thu Jun 28, 2018 11:53 pm quote
You do really nice work, solutions that are easy to service and look like they will last. I like the 2T tank w/ the easy to read oil level.
And this little number just kicks ass:


PS I'm liking your Pk style, even the color so despite your cheater motor, I think it needs to be here when done enough: PK love page .
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jun 29, 2018 5:43 am quote
V oodoo wrote:
You do really nice work, solutions that are easy to service and look like they will last. I like the 2T tank w/ the easy to read oil level.
[/img]

PS I'm liking your Pk style, even the color so despite your cheater motor, I think it needs to be here when done enough: PK love page .
Thank you for the compliment Voodoo.

When I get it finished, i'll post it over at the PK love page. Nothing says lovin like a pink PK.
Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jun 29, 2018 6:16 pm quote
since Iím not going to be using a normal center mounted brake light, I wired in a box that makes my rear turn singles also function as brakes lights. The control box got mounted up next to the Vape regulator.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jun 29, 2018 6:19 pm quote
And the rear LED signals/brake lights. I found them at a truck supply shop. Theyíre pretty darn bright in the daylight, so thatís a good safety feature.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:02 pm quote
Well the Nalgene bottle idea didnít go quite as well as I envisioned...so I bought a pink bottle instead. All is good now.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:06 pm quote
With it mounted up, it looks much better.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:07 pm quote
I also drilled a hole in the cap in order to install a one-way check valve.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:12 pm quote
And since I have a full 12 volt DC system, Iím using front LED turn signals as well. I found some 3/4Ē LEDs at my favorite trucker shop. They happen to fit absolutely perfect inside of my turn signal housings!

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:18 pm quote
I also decided to install a second LED in the turn signal housing to be used as running lights. I wired it up so that the second LED running light will turn on when the rear running light come on. Theyíre a bit hard to see in the pic because theyíre a fairly small surface mount LED. They emit a very nice glow after dark. It will also be a nice safety feature.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:22 pm quote
And now the reason why I tucked in that Nalgene bottle so far under the cowl area...

...I needed all the room I could get to bolt up a MRP storage box.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:25 pm quote
The MRP box doesnít come with any hardware, so I bought three 1/4Ē spacers and welded them to the back side of the box. It needs those spacers because there are indentations in the sheet metal, which wonít let the box bolt down correctly.

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Molto Verboso
Joined: 26 Oct 2015
Posts: 1855

Fri Jul 06, 2018 9:32 pm quote
I then used a countersink bit, so that I could keep the the countersink bolts nice and flush so that nothing rubs against them.

You can also see that I redrilled the holes. I needed as much room as I could get for that Nalgene bottle to fit, so I had to move the box about another 3/4Ē towards the rear of the scoot.

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Ossessionato
1976 Super (x 2), 1974 Primavera (x 2), 2006 Fly 150
Joined: 26 Sep 2013
Posts: 4905
Location: So Cal
Sat Jul 07, 2018 5:39 am quote
Beautiful work and attention to detail. Iím sure youíve thought about it, but with the bottle and MRP box mounted, have you left yourself enough room to fit a pipe and enough clearance for the rear wheel?
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