Small Update:
Modified my cylinder and head today to accept larger M10x1.25 Studs instead of the factory M8x1.25 setup. Like the 1987 Quadzillas the 6-Bolt cylinder/head on the 82-83 YZ490s like to blow headgaskets, so the fix is to use larger studs and increase the bolt torque. They remedied this problem by using 7-bolt cylinders/heads on the 84-90 YZ490 and 92-93 WR500. Got that all finished today, so hopefully everything works smoothly!
Also, made my new wiring diagram for my electrical system. Ignition side is pretty basic, wires to CDI then Coil, master switch, key switch etc. On the lighting/charging side, I am using a relay setup and master switch to have my electrical system run in three modes.
Mode 1: Off(simple enough!).
Mode 2: Charge (Current flows thru the charging relay and charges my on-board battery and provides additional power to my Trailtech Vapor Computer. Current is monitored thru a 20A fuse to prevent wire melting. The Vapor is setup to show available voltage at all times. When my charging system is "off" the trailtech runs off the on-board battery power, when I see this power start to fall off is when I switch it to charging mode. This will help me prevent over-charging of the battery which would happen if I didnt have a seperate charging circuit.)
Mode 3: Lighting (Using a diode, current will flow to activate both the Charging and Lighting Relays. Current then flows thru the Lighting relay to the H.I.D. Ballasts for each headlight and then power direct to the taillight. Between the relay and the Ballasts is a 15A fuse to prevent excessive current draw should an electrical fault occur in the ballast, don't want a fire! I measured the exact HID system I am going to use and on startup when they draw the most current i only saw 12A MAX, so I have some headroom here.)
I am using custom-wound Lighting coils and should be seeing about 95watts max capacity, the on-board battery will help to absorb the lower current situations when revolutions are not as high.
Heres my diagram, pretty much in its finalized phase.
Stator plate with custom-wound lighting coils installed and wired in. Floated ground to run to rectifier. Should put out approx 90~100w at 12v. Plenty for my electrical system needs.
Lastly, I cleaned up and painted my Banshee Hubs and installed new bearings(waiting on the seals from Yamaha). Also, painted my Norman420 spindles today.
thats all for now!
