Wisconsin Eco-Exo-R build by Edward

[roger32849]

Edward: I will be ordering my kit this week. My donor is a 2008 Burgman. I have the older front wheels and shock linkage. The engine is quite different but the mounts look close enough to say, they are the same as the 2003 - 2006. The cylinder head is thicker, but doesn't appear to be wider. It is also longer. I may have to borrow room from the area behind the seat to accommodate the fit. I believe I will have to modify my fuel tank or have one custom made. My modification would be to shave a notch from the bottom and have a flat panel welded in place. Naturally I do not have my kit from Exomotive yet, but I have been watching your forum entries as well as the big brother and Texas builds. The photos are very helpful. I would love to see a side
Profile picture of yours with the tall seat installed and the new fuel tank. It all looks good so far and the topics that you guys post have been food for thought for me. Here in Massachusetts I will be going through a lot of what you are doing to mine approved for the street, not sure about the air filter and/or fenders, but will look into it though.

You give a lot of good information, do a video of the 1st test ride and post it.

Roger
Worcester, Massachusetts

[edvb]

Rodger

Thanks. Jimmy is also helping with my build as I am a bit behind.

I will have my stainless rivnuts tomorrow so I will be able to mount my seat. The steering wheel is mounted to find out where to drill the holes for the seat rivnuts but that will be coming off so i can get the turn signal switches pre wired.

Both Jimmy and I will be using the Fiat steering column switches and
Fiat ignition swich and horn so I was able to trace all the circuits and with a couple relays I should be able to make it work reliably.

Fiat changes the wiring colors so you need to get the proper wiring diagram for your model year and type.

Your key will probably have a transponder built-in for the anti theft device so will be more complicated that what Jimmy and I have.

I found out that getting the engine and transmission mounted first and having a stand to build the trike helps a great deal.

I installing the steering column, Quick release and steering wheel.

Then I found the position that the seat feels best and mounted it midway in travel on my sliding seat mount. I had to remove the four studs so I had holes to mount the sliding seat mount to the rivnuts installed on the seat rails. The holes are drilled and I am ready for the install tomorrow.

The wiring harness has been taken apart and am working on what wires have to be lengthened to make a nice tidy harness. All wiring not being used has been taken out.

My A-arms have been blasted and painted in epoxy primer. I now can fit my bushings and start assembling the front end.

It all takes time but I would rather have all the parts ready to go than to do something ahead of time and when you get the part it does not fit.

Things are picking up and I should have a lot of progress made in the next few weeks.

[roger32849]

Edward: i will be starting my blog after I officially make my order for the kit. I have a lot of pictures of the newer engine type and mounts. If anyone has anything to add after I start, don't be shy. I will be doing a dry fit in my basement. I have a mig welder and some fabricating tools.. Also a small "A" frame strap hoist. I have located a reasonably priced powder coating business and believe I have most of my stuff needed to at least piece things together once I get the kit. I checked out the registry requirements and it is pretty cut and dry if I have a certificate of origin and a bill of sale.

The engine and all electronics are 100% complete and untouched by any modifications. The 2008 US/Canada spec models do not use a chipped key, so no worries about that part. Right now I have the harness laid out on my work bench and connected to the engine and all electronic components to include the fuel tank, the Oxygen sensor and fuel injection system and so on. I can actually start the engine If I wanted to. I am testing system integrity and replacing a few recalled electronics like the rectifier for one. My engine is painted, the muffler and other items are all ready.
Today I decided to go eBay and bought a 320mm steering wheel with horn and 6 bolt mounting capability, also put in a $152.00 bid on a vinyl reclining adjustable seat. If it lasts a couple of years, I can always replace it. It is a high back and looks comfortable.

Once I complete the build I hope to take it on the Blue Ridge Parkway and on to The Tail Of The Dragon. I am somewhat of a long distance comfort rider. I love the road bikes and that's all I have ridden. The reverse trike offers a lot of comfort and enough possible storage for a long outing. I am a retired person, so the building process will be my new job.. Life is great!!

If you read my post under the Powering Options heading, I outlined the differences that I noticed between the 2007 and up Burgman scooters and the older models. I have my work cut out for me

Thanks for getting back to me....

Roger
Worcester Massachusetts

[edvb]

Good for you Rodger!

Can you check the back of your ignition switch? There may be a cover but underneath you should find a resistor. Can you tell me what the color bands are? They should be Brown-Black-Brown-Gold.

Let me know. Thanks

Also some good news.

I got a new steering column switch assembly from Scott but the high beam contacts were intermittent when I tested it tonight.

I was able to disassmble both and swap the new stalks to the old unit and got everything working properly. It now looks like a new unit.

Well I am off to bed but a good day today.

[roger32849]

Okay, I checked the resister. The color bands are as you said, Brown-Black-Brown-Gold. I am not sure what the resister is used for, but hopefully you will fill me in. According to my shop manual, the US, Canadian,and California spec models did not have the chipped key ignition system. I have a plain brass cut key for mine and it starts the engine just fine.

Have you gotten your modified fuel tank made yet? That is a point of interest for me. My intention is to install the engine first as you suggested. I will also install the OEM air filter box and connect all hoses and sensors. After that, I will see what will fit where and maybe move the radiator to the right side to accommodate fitment. I believe the only reason it is on the left is because the carburetored models use the right side area for the carburetor intake. If I have to modify anything it will be the fuel tank. The kit was built very precisely for the 250 and 400 older model Burgman and Skyway scooters. Any other engine installation attempt requires modifications or a work around. I am prepared for a certain amount of that, just how much is yet to be seen.

It sounds like you are making progress with yours. Electrical work has never been my favorite, but I was actively involved in aircraft electronics while in the Air Force. It gave me a good platform to work from and it has held me in good stead when I need to fix, install or modify electrical circuitry. I use trial and error and "where's that smoke coming from" method of work. How about you?

It looks like I won the seat I placed the bid on through eBay. It is a reclinable/adjustable model. Black vinyl with a low profile seating area. It will accommodate the dual shoulder straps. According to the hyped up ad, it is a high quality drifters choice model. The same was said about the steering wheel. The price was right, so I will gamble a little on the reality of what it really is.

Tomorrow I make my order, and today I will call Kevin Patrick to get his bank information so I can get things set up through my bank to do the transfer.

Let me know about that resister in the back of the ignition. I am assuming it is a load to prevent voltage spikes to the ICU, but then again, it is only a guess.

Good progress on your trike. Tomorrow I officially will start my own blog on the build. I have several photos to load so will spend today placing them on Photobucket as the host. I will have to find out how to load them to the website.

Take it easy, any progress no matter how slight is forward momentum. Keep the info coming.

Roger

[edvb]

Hi Rodger

I sent a PM to you on the resistor in case the mods do not wish to have that public.

You can remove the photo as it is no longer needed

The tank is taking a little longer than expected and I have a few ends to take care of.

Once i get all the pieces together it should go fast.

Even today I got the wrong size tool for my Rivnuts so another few days of delay.

I got my A-arms back today after being primed so I can start installing the bushings this week.

Things are moving along.

I really like the quick release hub and by the end of the week I should have the wiring done on the switch column to see that the horn button will work correctly. I know all the other functions Headlights, Hi-Low, Sidelights and turn signals will work fine.

[roger32849]

Edward, can you measure the distance between the mount points of the rear shock and send it to me. The shocks are a little different and I want to make sure at least they are the same length. PS: I placed my order and Kevin sent the Ebook for the build.

[edvb]

Well I worked at getting my steering column switch harness made today.

I now have my horn button, Headlights High Low and Pass, Running lights, and Turn signals all made up with a disconnect for the assembly. I also have the Ignition switch all configured without having to use any relays. All I will have to do is lengthen the wires and crimp on some .250 female disconnects. Everything will work as intended including Parking lights and lockable ignition and steering. I only will have to add a lighted Emergency flasher switch but the wiring is already there in the loom.

Getting all the sub Assemblies made and figuring out the loom to make it nice and neat takes time but it should be plug and play when I get done.

I really have to thank Jimmy as it was his idea to have all the functions and lockable steering work with the Fiat Ignition and steering column switch assembly. I also wanted the center horn button to work so we accomplished that goal today.

I also install the Rivnuts and mounted the seat. I lucked out and everything fits well. The seat slides smoothly fore and aft and the lever fits nicely under the seat. I will weld a small bar across the front of the two seat rails to mount the Rear shock adjuster just to the left of the seat adjusting lever.

I will take some pictures tomorrow with the seat fore,aft and my normal seating position. Everything is starting to gel together.

Rodger I will check that tomorrow morning.

[roger32849]

Edward: it looks as though you have been in the garage/workshop again. Congratulations on the wiring job. Is that the handlebar control wiring harness I see mated to the Fiat switch assembly? It looks OEM!! I have been reading through the build manual that Kevin sent. It is some very interesting reading. I also heard from Scott Turner and he is looking forward to the order. I figure after the Easter holiday weekend Kevin will shoot it off to him.

I also have been reading the SEMA inspection guidelines for kit car inspection here in Massachusetts. Not to much about motorcycles, other than the obvious lights, brakes, horn and emissions. They did say that if you have donor parts make sure you have receipts with VIN numbers of the donor vehicle(s). No receipts, no title!! It's just that simple.

Thanks in advance for sending the shock measurements. The shock I have has a manual adjustment instead of the remote regulator. Since it is different, I wanted to see If it was at least the same length.

Can't wait to see the pictures. It is great you and Jimmy can work together, especially when you are so geographically detached. Lets face it, Texas is not exactly a suburb of Oshkosh... The Internet is truly a great tool for communicating.

Roger

[edvb]

Rodger

I measured my shock and I came up with 13.75" center to center on the two bolts.

I found some connectors at the auto salvage and was able to use some of them after a bit of shaping on the grinder to fit the steering column switch contacts. I also wanted to have a quick disconnect so I could remove it if I needed to remove and repair something on it. The other side still needs to be installed into the main wiring loom.

I have been working on the main wiring loom cleaning it up and it looks like I will need to extend it about 42" from the main wiring going back to the engine. The resistor is soldered and heatshrunk into the harness where it will be protected. I have to find some wire to extend the loom this week.

Overall rewiring the main loom is not too bad and all the relays, ECM and most of the plugs will fit right above where the steering column is bolted on.

The relays for the Headlamps, Horn, Turn signals, Running lights and Brake lights will be mounted in the same place above the steering column. I plan on having a few more and brighter lights installed so the relays will take the load off the steering column switches no matter what I install later on.

This will give me a place to have a nice clean layout that is protected from the elements and heat from the engine.

I will have pictures later today.

The Rectifier will be mounted on the rear engine firewall.

Overall I am moving forward.

[roger32849]

Thank you, 13.75 is the magic number. Just waiting for stuff to happen. Waiting will be tedious. LOL. I can always polish stuff and get my wheels powder coated..

Roger

[roger32849]

Thank you, 13.75 is the magic number. Just waiting for stuff to happen. Waiting will be tedious. LOL. I can always polish stuff and get my wheels powder coated..

Roger

[edvb]

Boy! don't you hate it when you just finished installing something and re-test it and it just does not feel right.

My seat was that way. After getting it installed it just was not tilted back enough. I tried different angles with my trusty wife shimming it up and down while seated until I found it comfortable.

The seat had .500 spacers to clear the adjustable mechanism but I can get by with .250 in the back and 1.250 in the front.

That is .250 closer to the ground for that speed effect at 85 MPH.

I am like Erik, Anal about every detail but that seperates the men from the boys so to speak.

I cleaned the shop today and getting things in place.

I also figured out my parking brake and am working on getting that part.

Overall a good day and moving forward.

[edvb]

Well I got some spacers made and mounted my seat. It is just at the right angle and I almost went to sleep in the trike ;D

Here are some pictures of the seat adjusted for me. By tilting it back it really fits the trike just about perfect. Now for that custom padded cover to really make it stand out.

[jimmybcox]

Good job Ed!