XL500S Rewire is complete!!!

 The rewiring is complete - showing headlight housing.....

 Ignition key mounted in place.....

 Main wiring harness and flasher relay....

 Box with the cream panel at top left is the 6 volt to 12 volt converter to power gauges....

 Rear lighting harness......

Speedometer seems to work and is calibrated for 25 inch diameter tyre. We have a nice healthy blue spark, so we are ready for a test start.....

Danmoto SP4 speedo sender installation

I decided to mount the speedo sender to the rear wheel because its a neater looking install. The sender is mounted via a new hole in the brake torque arm (at top right of this pic).

The speedo sender mounted in place on the wheel.

The magnet will be glued in place on the spoke flange between  two spokes.

And here is everything mounted in place. Looks neat! All that is needed to operate is progamming the wheel diameter in, which is 25 inches and it works!

Front wheel cover

The cush drive side of the now front wheel needs to be covered as its just plain ugly. So I purchased this enfield seven inch brake plate for $15 and modified it to fit.

I made a much larger hole in the middle to clear the bearing area and bolted it through from the brake drum side. And made some threaded bushes which I cut off from the back of the new part!

Just needs to be painted........

Key ignition switch mounting in headlight mounting ear

I was wondering where to mount the key switch? The new headlight brackets are positioned in a convieient place and have holes in them already. So I just needed to make one of holes slightly larger and voila, its done!

Front mudguard mount using pergola brackets & chain

Step 1 - buy some pergola brackets from bunnings,costing 4 x 60c = $2.40

Glue two together back to back with epoxy glue. Then drill some mounting holes in the channel shaped brackets, they are counter sunk to clear the tyre.

I had some chain off-cuts which I bolted to the mudguard. You can see above where the holes will go to bolt the chain to the channel shaped brackets.

You can see here it is all bolted up in the correct position.

Now all I had to do was trim off the brackets so it looks nice and neat. And we are done.