Lightweight Shorai Battery

Not a vintage project but a cool one. I wanted a new battery for my 2010 Husqvarna TE250, and had recently read about these cool lightweight LiFePO4 (lithium iron phosphate) batteries made by Shorai. I'm a novice in the dirt and I'm short so the idea of lightening the bike a couple pounds sounded like a good idea.

Shorai's "Standard Recommendation" for my bike is the LFX09L2-BS12. There website claims: "This LFX battery is 4.07 Lbs. lighter than the lead-acid YTZ7S." That sounded pretty awesome, and my local dealer had it in stock.
Here is my original battery and the new Shorai.

The new Shorai is significantly shorter and less deep. They provide foam that you can cut to wedge the battery in the battery tray and you can see that in front of the Shorai battery in the picture. They also have these nice bolts with foam underneath that helps raise the nut for fitting the bolt. If you have fit a motorcycle battery before you know this seems like a handy and nice idea.

But what about the weight? First I weighed the original battery.

 

This is the original battery that came with the bike and including the bolts it weights 4 pounds 8.5 ounces (4.53 pounds).

Now the new Shorai battery.

Wow! 1 pound 4.9 ounces (1.31 pounds), including the bolts and foam shim.

So that is a savings of: 3 pounds 3.6 ounces, or 3.2 pounds. Not really close to Shorai's claim of 4.07 pounds, but still a pretty good weight savings.

Here's a picture of the battery fitted to the bike.

I was careful to zip tie the battery in place, as it definitely cold come loose otherwise, due to it's smaller size. But it does fit really well. (You might notice, I have some extra wiring under my bike for the Power Commander.)

I checked the voltage of the battery when I bought it, and it was at 13.40V. Which Shorai claims means the battery as delivered was at more than 90% charge. I also checked the drain with the ignition off and got 0.17mA on my meter. Thats pretty small, but I think I'll leave the battery disconnected between riding trips.

Cost? The Shorai at $106.62, tax included, was about the same price as a replacement Yuasa MF YTZ-7S battery ($110 online from various sites). But you can get an off-brand sealed AGM YTZ-7S for less than $50. So it's a great deal if you compare to a high end OEM replacement battery, kind of expensive if you compare it to the cheapest batteries out there.

So thats it, probably the easiest 3 pounds I've ever saved on a bike.

How I bent the foot peg mount back

The right foot peg on my 1977 Kawasaki KH400 has been a little crooked. Ideally this would have been bent back while the bike was disassembled (during restoration) but the restorer didn't notice it at that time.
The threaded lug that receives the foot peg is mounted to a gusset on the frame and I could see that gusset was slightly tweaked. So it wasn't a matter of bending the frame, just tweaking the sheet gusset back straight.
I tried bending it by removing the foot peg and inserting a long bolt, but the bolt just bent. So I ended up buying an extra foot peg on ebay, and then cutting it so I could fit a long steel pipe over the end.

I wrapped the end of the pipe in tape to protect surrounding components if something slipped or broke during the procedure. I also heated the the gusset with a heat gun. Not too much as I didn't want to harm the paint. Just slightly warm to the touch. Then I had my wife support the bike so I didn't pull it over and carefully tugged on the pipe. It's delicate procedure, as I didn't want to break anything and there are big, potentially dangerous forces involved. Obviously we both wore gloves and safety goggles. If you try something like this, be very careful and really, get professional help.

Mondial Repairs

I arrived home from the giro and quickly made a list of things that need to be repaired, fixed or upgraded on the Mondial. These old bikes always need something. Sometimes the problems just arrive and sometimes they are chronic things you just can't seem to get rid of.  Eventually I might decide to move to a new old bike and a new set of problems!

The problem at hand:

- the ignition switch is intermittent and the ignition can cut out while riding or sometimes just to prevent the bike from starting.

A little investigation showed that the flat contact spring for the contact on the switch is made of two pieces, and one of the pieces has broken. (You can see the broken flat contact spring on the switch on the right in the picture below.) Unbelievably, I was able to find a replacement switch easily on sale for a mere $36. Its slightly different, but no big issues.

The new switch is on the left in the pic, with the bulb and fuse already fitted. I also put a jumper on it to connect two of the terminals. 

So now the switch is fixed!