Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums - RoadHopper's Album: Battery Cage and R/R relocation
 
Battery Cage and R/R relocation
Corrosion had eaten away at this entire section. Plenty of rust and faulty connections. The R/R was relocated to under the left cover. This was mainly for ease of replacement rather than cooling, but it is probably cooler there than under the cage since heat rises and the R/R heat sink was mounted on a "ceiling" under the cage. Its new position allows it air on all sides.

After removing various parts, all of the exposed electrical tabs were cleaned with contact cleaner and a wire brush. On reassembly, WD-40 was applied to all bolts.

Photos from bottom to top show rebuilding of the battery cage after hand sanding and painting with high temp BBQ grill black.
Left side showing the R/R in its new home.
Right view after all parts remounted.
Top view of cage installed
Left side after cage installed
Preliminary mounting of the cage.  Engine ground wire was put behind the upper right hand mounting bolt later.
Photo shows testing one of the bolts of the ignition coil.  After testing each of the bolts for each of the parts, it is evident that two coats of...
The cage was painted with two coats and the bolts were treated with WD-40. The question now becomes: "Will the cage act as ground for all of the...
Final assembly of the R/R onto the cage.  The standoff supplied by the bolt is now evident. Air can pass around all sides of the heat sink.  The R/R...
The same bolt that holds the J/B retainer onto the cage will also now hold the new R/R mount.  Photo shows lining the two pieces up with the hole in...
A side view shows how i mutilated this poor conduit holder beyond recognition.  The curve will supply enough down pressure spring to hold the R/R...
This view shows the underside of the attachment.  It came with a square offset bolt.  I am giving that bolt's head a new function in life to act as a...
This metal strip was formerly an electrical conduit holder.  In this top view photo, its width can be seen to fit snug square right into the fins of...
Turn signal unit attached to the cage after cleaning.  The female Molex connector will be cleaned along with its male partner later after the cage is...
Ignitor box attached to the cage.  After its removal, its cover was removed and washed with soap and water. After drying, the plastic housing and...
Before installing the cage, parts are reattached which are otherwise impossible to reach for removal.  To allow the cage back into its hole, however,...
Excess cable tie removed with wire-cutting pliers.
Bottom view of cage with battery seat installed.
Top view of cage with battery seat installed.
Boring the second set of holes from the underside of the cage.
Cable tie pulled taught, its head prevents it going further.
Threading the cable tie through the foam
Threading a cable-tie through the bottom of the cage, into the holes made by the probe.
Using a probe to bore a hole from the underside of the cage through the holes previously used to mount the R/R.
Folded foam goes on top of the original rubber seat.
Cut twice the size of the seat, folding the foam in half doubles its thickness.
 
 
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