2009 November 06: Wiring (3.50 hours)

Updated: 2009 November 06

I spent nearly the entire evening working on how the wiring is routed. I had a nice set of large digital images from an unmolested G5, and those were very helpful. But, I had some extra wiring to deal with. Like most Tontis of this vintage, the front headlight is missing - long ago replaced by a Vetter or Pacifico fairing. Good used headlights are difficult to locate, expensive, and were never of the best quality to begin with. Furthermore, I moved from Police handlebars to Civilian handlebars - giving me some extra length in the wiring harness to deal with. Since I was no longer using the original coil mounting location for the coils, I had free space there. I used that space and routed the wiring accordingly. It took a good bit of time, but the end result is pretty neat and tidy - especially between the headlight and the triple tree. I also got the frame grounds taken care of. Rather than removing he powder coat at each grounding location, I simply used a bolt to secure all of the grounds together on the frame and then ran a ground wire back to the battery. This makes for a very clean installation and grounding is assured.
Lubricated a new pair of throttle cables.