ATE Caliper Rebuild

Time to rebuild the brakes.

Calipers need to come off.

Calipers are in good shape.

All seems well after disassembly.

There is some rust on one of the pistons.  Going to order new pistons.

Master cylinder is ready for removal.

master cylinder

Master cylinder is off.

Brake lever and cable is in good condition.

Enduralast Wiring for the '75 R90S

Enduralast Alternator System Wiring Addendum:

For 1974-76 R90/6 and R90S.


My Bikes:  1974 R90/6, 1975 R90S, 1976 R90S.

1.  Diode Board on a ‘75 R90S

•  Diode board has two (2) red positive (+) wires going to: 1) starter solenoid, and 2) starter relay.

•  Red wire to starter solenoid is discarded with diode board.  Red wire to starter relay will be cut at diode board, and later re-connected to starter solenoid (+) post.

2.  Starter Relay, ‘75 R90S

•  Stock wiring:  from starter relay - red & blue go to diode board, black goes to starter solenoid trigger terminal.

•  No “white plug” on older /6 models; blue and black wire are connected to the starter relay.

3.  Wiring Harness from Starter Relay

• Black wire goes to starter solenoid.
• Red wire was attached to diode board.   Ring terminal has been attached to end, will be reconnected to starter positive post.
• Blue wire was connected to diode board, will be reconnected to white wire from Enduralast Regulator

 4.  Red wire from starter relay, was attached at diode board

• Removed female spade terminal

• Attached ring terminal
• Reconnected  to starter solenoid positive (+) post

5.  Stock Wiring Sketch 

• Stock configuration diagram oversimplified to show only wiring altered in installation

• DB - diode board

• SR - starter relay

• SS - starter solenoid

• VR - voltage regulator

6.  Alterations to stock wiring

• DB - diode board

• SS - starter solenoid

• SR - starter relay

• VR - voltage regulator

• Blue wire from SR is cut at DB, will be re-connected to white wire on Enduralast Regulator

• Red wire from SR is cut at DB, install ring terminal an connect to SS positive (+) post

Discard old DB and old VR and discard old red wire from DB to SS, as per Enduralast instructions

7.  Completed Enduralast Wiring

• Blue wire from SR is connected to ERR white wire

• Red wire from SR is connected to SS positive (+) post

• Black wire from SR is reconnected to SS trigger terminal

• All other wiring is connected following Enduralast instructions:

• Red wires from ERR are connected to battery (+) post or to SS (+) post

• Yellow wires from ERR are connected to Enduralast Stator yellow wires

• Black wire from ERR is connected to (+) with key ON, such as coil, as per Enduralast instructions

8.  Photos below show the red wire from ERR passed through grommet with positive (+) battery cable, and is connected to the starter (+) post.

• new battery cables from Euro Motoelectrics (EME).
• new starter from EME
• red wire from ERR is connected to the (+) battery post, or in my case to the (+) post on the starter
• my ERR is mounted in the stock voltage regulator location, red wire to starter (+) post is short length.

9.  The Enduralast Alternator

Regulator Mounting Plate

Alternative Mount for the Enduralast Regulator/Rectifier

1.  Stock voltage regulator location.

·      Regulator removed, frame sanded to bare metal.

2.  Mounting Plate

• Drilled and counter-sunk.
• Pan head screws are used in place of stock socket-head bolts.  
• The regulator is mounted directly to the plate, over these screws.  The screw heads must not impinge on the regulator's underside

 

 3.  Plate mounted to frame.

• I re-used the ground wires that were previously removed with the diode board.

 4.  Eduralast Regulator/Rectifier (ERR) Mounted

• All metal-to-metal contacts sanded;  heat sink compund applied.
• Ground wires attached to back side of mounting plate; bolts through ERR secured to plate.
• ERR is well clear of gas tank and engine case.  Exposed to air stream; should be more than adequate cooling air.

5.  Back side (left side) of mounting plate.

• I used M5 nuts and lock washers on the pan-head screws for secure mounting of plate to frame.

6.   Tank and ERR in place.