Has anyone found a source for the white high temp fiberglass sleeving used on the points wires? I found some at McMaster-Carr, but it says 1/16 wall thickness. Not sure if that is correct, but that's a lot thicker than the stuff used on our bikes.
I've tried electronics, electrical and appliance supply houses locally with no luck. I did find 5/16" at a burner control place and am taking a ride over to look at it. I think it is too large a diameter. Ours looks about 0.200 OD which is about a 3/16" ID.
Thanks,
Rob
Fiberglass sleeving for points wiresAfter many hours on the web searching for source, I was unable to come up with a source for the white fiberglass sleeving that goes over the points wires on my CL77. I did find many sources, but had to buy complete rolls of the stuff and gave up.
I talked to Beatrice Cycle (Dr. ATV) about the sleeving they have for S90 bikes and they were not sure I could get 2 14 ga. wires thru it. I figured I'd give it a try and ordered 4 feet of the stuff. Well, with a little finesse, you can get 2 14 ga wires thru that sleeving. I had to run a polished 3/16" rod thru it first to open up the ID a bit. I then fished a couple of strings thru it with a wire and pulled the wires thru. Needless to say, you have to remove the terminals from the two wires before you can do this. So, although their sleeving is smaller ID than what came originally on the bike, it can be made to work. As them to put the sleeving in an envelope and ship via 1st class mail. It will save you about 4 bucks in shipping over Priority Standard rate box, which is their cheapest published shipping method. A side note is when I removed the old sleeving, I found the wire insulation was chafed on both wires in the same spot for about 1 inch. On one, it was just about down to the wire. So I put shrink tubing on the bad spot which is hidden by the white sleeving. The fiberglass is somewhat abrasive and it will probaby saw thru the cotton insulation if pinched or placed improperly. Next project, new silicone rectifier. regards, Rob
Good call, Rob, and a nice find.
That length of wiring is a part of the condenser ass'y and, consequently, comes with it; I was lucky enough to spot a NOS condenser on eBay with a BiN (US$30, I seem to remember) price. It's not installed yet, as my motor has been a bit mucky; both the motor and your hands need to be spotless before fitting the new one, otherwise it'll end up looking like shite! Motor's out now, for surgery. It's little details like your replacement process that make your own machine what it is. My condenser pack is fine (knocking on wood here). But the sleeving was shredded up on top of the engine and it bugged me.
Regarding the rectifier upgrade, I compared my S90 charging system to the CL77 and they are identical, wiring-wise. Might be a wire color difference here or there on some models, but where each wire goes is identical. I was not sure if a rectifier upgrade instruction existed here for the 305's. If not, I have one from the S90 site that makes it simple, even for the electrically challenged. Here's the diagram. Do you know if we have a write-up for this already on the site. If not, I'll make a sticky with the write-up and include the diagram. regards, Rob
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