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Thread: Sachs xtc 125 conversion

              
   
   
  1. #91
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    Hi
    Fuse(es) arrived, but my buddy being sick i am still waiting for the sens-wiring.
    In the meantime i got some open tasks done:
    -new break fluid
    -pre-alligned the motorplate in relation to wheel/ chain..
    -got the grips /throttle on the handlebars
    -aux battery is in
    -final mock up of the new cockpit... as i forgot to put the 12v display onto the first one..

    aux battery in original location:
    CIMG0597.jpg

    final cockpit:
    CIMG0602.jpg

    with a bit of notching:
    CIMG0596.jpg

    the fairing nearly closes

    ( it does in the back but with a slight relocation of the pack- to leave more room for cables- and the cells being wider than advertised my plan did not work out fully)
    CIMG0595.jpg

    It will look something like this in the end:
    CIMG0601.jpg

    greets

    flo

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  3. #92
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    HI
    never waste any material
    CIMG0610.jpg

    Half of the chain guard done...
    would be finished by now if i was one to stick to his own plans..
    used up the other motor-cut-out to mill those stops for the craddle instead of milling them from other leftovers seperatly..
    well need tho order another piece of aluminum...
    CIMG0617.jpg

    greets

    flo

  4. #93
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    better view
    CIMG0615.jpg

  5. #94
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    Wiring sheme

    anyone cares to have a look ?
    hope its all really visible.
    Most important to me is the former indicator light that i have circled into that blue oval.
    Will this indicator light be on only after the contactor closed? (and not causing short that is..)
    Attached Images Attached Images

  6. #95
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    Flo
    Is pwr the ignition on switch? Then I agree it should only come on with the contactor as the circuit will not be live otherwise.

    Someone please correct us if we're incorrect.

    Cheers

    Tyler

  7. #96
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    Pwr on the controller pin 7 should come live and close contactor of motor pack only after key switch is closed
    and the "e-stop" on handlebar is closed. I called it contactor on switch)
    Otherwise key switch only turns on lights, indicators, break, horn..
    Last edited by flo; 07 May 2019 at 1509.

  8. #97
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    Hi
    got the upper pack (10s) finished with sense cables and fixed to the bike - no pic though

    Holder for the emergency cut off done:
    CIMG0621.jpg

    fits nicely:
    CIMG0622.jpg

    Now i had to get it not only attached to upper battery pack but also line up the hole in the tank for it to go through...
    all nice to have cnc and cad at hand but an with an unknown shape - hmmm
    Some rocked sience was on order - using a high tech aproach for lining up:
    CIMG0623.jpg

    together with the most advaned tools:
    CIMG0626.jpg

    produced a nice coutout.

    now only glue on and make sure it doesn`t wander off downwards

    tape and another high tech helper:
    CIMG0628.jpg

    stay tuned

    greets
    Flo

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  10. #98
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    Hi
    time for an update:
    Got nearly all the 12 V cables done new. minus the indicator lights and CA in cockpit and Contactor switch to controller.
    Been wondering for quite some time as how to prevent the upper pack from swaying sidewards (only attached generously on bottom).
    While doing the Emergency cut off`s cutout it finally came to me.
    Why not use the former Fuel intake opering- which had to be covered anyway -to arrest the battery?
    Milled up a centering part and a new top (might get engraved in future).
    Works brilliant:
    CIMG0631.jpg
    (will show inner part tomorrow)

    This houses the main fuse, aux charge plug and will house the charge plug for main bat..
    CIMG0632.jpg

    In the meantime i am wondering if this direct connection of fuse and contactor really is advisable.
    Or would it be better to use a short cable to enable some flex between the parts?
    Any advise?
    CIMG0633.jpg


    getting closer...

    Greets

    Flo
    Last edited by flo; 22 May 2019 at 1225.

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  12. #99
    Senior Member Stevo's Avatar
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    I mounted my main fuse to the battery + attached to the contactor also. Located inside one of my batt box compartments:
    IMG_20190519_133239.jpg Its hard to see, but the contactor is secured in dense closed cell foam rubber. There is a short length of cable to battery + and a piece of angled Cu on one side of fuse to attach the cable to
    IMG_20190521_081542.jpg
    I don't see a problem with this idea, as long as there is no physical stress on the fuse itself and the contactor is securely mounted. Cheers!!
    Last edited by Stevo; 23 May 2019 at 0847.
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: eVOR.v3.3
    WORX.VOR.v3.2

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  14. #100
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    Hi
    thanks for your support
    Just finished mounting it the way shown above...
    no pics yet as it was getting dark when done. But i will show the outcome. All save inside the tank and attached to batterybox.
    Only a few more cables till a testrun may be possible.

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