‘70 Commando Roadster rebuild in GA

Rotate that black pressed panel behind the rear light lens for a 180° so the lower curvature points toward the lamp holder.
The way it is mounted now it blocks the license plate illumination.

Much appreciated, Rivera.

I just pulled the horn and tail section from storage, prepping for install and harness placement. I now have a good excuse to take it apart and properly clean and rearrange the previous setup.
 
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Thanks, Pete and Frank.

I’ll search for the LED replacement. Had to make that switch with a cargo trailer in order for the tow vehicle electrical system to match power draw, made a big difference.

Is there any change necessary to the stock electrical system setup to be able to accommodate the LEDs? Or just plug and play?

Haven’t been home in a while to study the drawings/diagrams
 
I got my bulb here. http://www.dynamoregulatorconversions.com/led-bulbs-especially-for-motorcycles-shop.php

I think I got this LED

‘70 Commando Roadster rebuild in GA
 
I bought LEDs from the firm mentioned in the post above, They also sell LEDs for positive grounded vehicles.
I use them for my instrument lighting , control lamps and rearlight.
I guess they are not street legal in Germany for the main beam.
 
I bought LEDs from the firm mentioned in the post above, They also sell LEDs for positive grounded vehicles.
I use them for my instrument lighting , control lamps and rearlight.
I guess they are not street legal in Germany for the main beam.

Good to know. No issues since installing, I assume?
 
There are a few electrical configurations depending on the model. I use an ammeter on my '70 (which I mounted in my headlight shell) If you have a workshop manual, the ammeter is shown in the schematic of the simple electrical diagram in the back of the manual. (I'll also paste the image below) I also added directionals and late model switch blocks to my bike, because even though directionals aren't required for vehicles made before 1973 in the USA, other drivers don't pay enough attention to be safe only using hand signals. (You add a hot lead from the ignition switch into the headlight shell and feed power to both switchblock cables from it, then add the wiring to the new directional lights from each switchblock and then ground the component to the frame... done)

Electrical work is logical. So long as your are making compete circuits, you have options. I wire my headlight shell lighting switch to the positive side of the ignition switch so the lights go off when the key goes off, and the only things that are hot without the key being on, are the horn and the main beam flash. (the schematic below illustrates this)

I have a 3 position headlight switch which is wired as:

Left position ------------ Center position --------------- Right position

OFF ------------------- Daylight bulb and tail lights ----- Headlight Plus Daylight bulb and tail lights


"OFF" is to kick the bike over without any draw on the battery besides the ignition circuit

"Daylight bulb and tail lights" only was to reduce electrical usage originally, but with the LED headlight bulb I use, it's not much more efficient than having the headlight LED on, so I rarely use the middle position anymore

"Headlight plus all lighting" is my normal position to ride the bike. Everything is on, and the ammeter shows positive charging above 2,000 RPM's, which is pretty decent. When I idle at a stop light the ammeter is in the negative for a few minutes. When I take off it charges strongly for a few minutes to restore the lost surface charge, then goes back to it's normal position, slightly charging as I ride along normally. I recommend an ammeter, but many are critical of them, so there's some homework to do if you want to install one.

‘70 Commando Roadster rebuild in GA



As far as Pete's "rat's nest" goes, I don't mount my terminals toward the rear because I like to keep the rat's nest away from the terminals. I cut a 1/16"th thin sheet of stiff polyethylene to go between the battery and the back of the oil tank and I put the terminal connection side of the battery facing the oil tank behind the insulating sheet of plastic to prevent accidental contact with anything metal.

long winded, no doubt...


We spent a good bit of time trying to match up terminals with wire colors yesterday. It’s no rat’s nest, but we are now wondering if the harness is original or if it was modified.

‘70 Commando Roadster rebuild in GA

Luckily there are two of us scratching our heads at the same time. And he doesn’t mind getting paid in Mexican dinners.
 
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I think the commando had a 9 AH requirement for it's battery originally. That kind of specification is based on the charge rate of the stock rotor/stator and the demand of the components. (ignition/lighting/etc) There's no electric start on a '70, so you really don't need a powerful battery. You can even lower the electrical demand with an LED headlight bulb. I use the one "dynamoregulator" makes. It is bright as hell and draws less amperage than the stock bulb and drops right into the stock headlight bucket and uses the stock electrical connector. It's worth buying for the safety factor alone of a more powerful headlight beam.

If you have an ammeter on your bike, you will see the interplay of your charging system and your battery as your RPM's change. On my commando, at about 1800 RPM's the bike is charging the battery. Once you begin riding your commando, you'll realize that charging threshold is low enough to keep your battery charged during normal riding. Maybe if you were riding in a parade for a few hours, you would benefit from a more powerful battery.... Parade much??

The only time the bigger battery is better is, if your charging system fails and you are limping home on battery power... but if you have the bigger battery, but no ammeter in your electrical system, then you're not going to notice the charging problem as soon, so maybe it evens out...

Thanks. The battery strap is another mod waitin’ to happen.
 
Franks post above is good advice. Given your comfort level you may or may not be confident tackling your own customizations. There seems to be a constant draw on the battery even with the key off so I wired in a simple on off toggle switch that cuts all power on my bike. Did you ever have this issue Frank?


I also protect my terminals with a thin plastic battery cover. I do miss that rats nest though. Here are some more grim photos for fun. Maybe you can pick out something helpful amidst the grime

‘70 Commando Roadster rebuild in GA


‘70 Commando Roadster rebuild in GA


Through the headsteady! Ill have to fix that detail.
‘70 Commando Roadster rebuild in GA

Brake lead detail

‘70 Commando Roadster rebuild in GA


More rats nest
‘70 Commando Roadster rebuild in GA

Tail light route.
‘70 Commando Roadster rebuild in GA


Inside the bucket

‘70 Commando Roadster rebuild in GA

Your pics were a great reference, Pete. Helped keep our momentum going, even though we were stumped by dinner time. We’ll regroup and continue in a few days.
Thanks
 
OMG BusDriver, everything is so,..... clean. Mine looks nothing like that... :cool:


Once you finally do get it all going, be very concious of getting a good tight twist on the oil tank cap. If I fill the oil tank to the F line, it tends to come out the Cap. If the level is midway between F and L, and the cap is on tight it's less likely to leak.
 
Looking gooooood.
The upper banjo feed bolt on your oil tank needs to be spun around so that the chain oiler spigot is facing to the rear of the bike. Or just plug it and call it done, which is what you should do anyway once it is in it's proper position.

Also it appears you have solid rocker oil feed lines. I would look into replacing those with braided stainless lines. As the solid line is not original to the bike and likely to break.

You are getting close to the end, enjoy it while it still lasts!
 
OMG BusDriver, everything is so,..... clean. Mine looks nothing like that... :cool:

*I can fix that real easy after the first ride, if there is a first ride.:)


Once you finally do get it all going, be very concious of getting a good tight twist on the oil tank cap. If I fill the oil tank to the F line, it tends to come out the Cap. If the level is midway between F and L, and the cap is on tight it's less likely to leak.

*I’m using an original cap and thinking I may need to look at that lid gasket. Gotta be some modern fix for that leaky-ness.
 
That’s one of many problems. The oil bolts aren’t secure. Neither relief line is secure also. I throw things on and see how they fit and reinstall a few times before I do the final deed.

Like the front wheel. I put a vintage looking tire on that looked great. I liked the look of similar sized front and rear, like the later 850s. The front mud guard did not like my choice at all. Not to mention the handling handicap. So I’ve installed the front wheel 4 times and mounted 2 tires to get to this point.

Just threw on the rear mudder to view the fit and will probably remove and treat all the fasteners before a final fitting. Glad I have a day job.

The chain oiler is a definite delete and I have the braided oil line, just haven’t installed. I was not aware the solid line was not standard, though. I grabbed the braid because the existing line had a few wanky bends that made it look suspect.
‘70 Commando Roadster rebuild in GA


If the wiring and component mounting around the battery area doesn’t drive me insane, we’ll get there, I hope.
 
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Do you have the later style rear wheel hub with rubber cush drive in it?
I see a solid side cover.
Mine has the original three bolts to fix it to the rear brake drum.
The cover has three holes for the studs.

The rubber plugs appear to be white?
 
Do you have the later style rear wheel hub with rubber cush drive in it?
I see a solid side cover.
Mine has the original three bolts to fix it to the rear brake drum.
The cover has three holes for the studs.

No, the three plugs are just white. Not sure if that was original either.

- should I have replaced it? The hub?
 
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