XR650L: Shorai Battery Relocation

Discussion in 'Thumpers' started by Spud Rider, Mar 7, 2011.

  1. Chad M

    Chad M A full head of air.

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    Sorry Spud, I don't know which particular product you should use, I do know there are some very coarse velcro styles that would suit your purpose very well. I'm certain you can buy sheets that you can trim to fit the battery.

    Cheers.
    #21
  2. Spud Rider

    Spud Rider Long timer

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    Thanks for the reply, Chad. :nod I have used the 3M, Scotch, Dual Lock Reclosable Fasteners before; they hold a lot of weight, so I am sure they will securely fasten the Shorai battery to the top of the air box. :nod

    However, I am certainly willing to experiment with some of the very coarse velcro styles you mentioned. Can you recommend a place where I can buy some of this velcro?

    Spud :wave
    #22
  3. Ben99r1

    Ben99r1 Long timer

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    The one I got from wally world is a heavy duty velcro. I need a credit card or screw driver to pry it apart. I also use it to hold my HID ballest to the frame of the bike. Ben
    #23
  4. Spud Rider

    Spud Rider Long timer

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    Today I went shopping for velcro. :bore I bought some "Industrial Strength" Velcro at the fabric shop, and some Scotch Heavy Duty Fasteners at Staples. However, when I returned home to remove my battery, and apply the new velcro, I discovered the battery was very firmly attached. :rayof The 3" x 2" piece of Scotch Multi-Purpose Fastener I applied to the battery is doing an excellent job, so I am leaving it alone! :wink: I am confident the battery will not shift position using the present "velcro." :D

    Someone on another forum requested photographs showing the location of my repositioned starter relay, and fuse box; therefore, I will post those photographs here, as well. :nod

    [​IMG]

    [​IMG]

    Here's a top view from the left side of the bike, showing how the right side plastic covers the starter relay.

    [​IMG]

    Finally, here's a view from the right side of the bike, showing how the saddle overlaps the right side cover, protecting the starter relay from moisture. :nod

    [​IMG]

    To better protect the fuse box from moisture, I have decided to extend the wiring, and move the fuse box under the saddle. Other than this final modification, I consider my Shorai battery relocation to be complete. :D

    [​IMG]

    Spud :wave
    #24
  5. Spud Rider

    Spud Rider Long timer

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    Thank you, Kawidad. :D

    Spud :wave
    #25
  6. ONandOFF

    ONandOFF more off than on

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    Super, Spud :wave I'm loving your mod from a distance; it's so well thought out and documented. So in practice, how does it feel in terms of handling the bike??? :ear

    I see what I might consider a slight drawback to the fuseholder location. If a fuse blows out on a ride, will it be necessary to have tools along to access it for a change?

    I think extending the wiring to it is an invitation to later problems. But not absolutely so. I'd reconsider.

    The problem I've had with velcro fastening isn't the velcro itself, but rather the adhesive holding the velcro to the opposing surfaces. While it's great new, it doesn't take a lot of time, especially with heat and damp cycles, to cause it to dry out and let go. So you're left in the breeze, so to speak, with the two velcro halves still solidly attached to each other :augie
    #26
  7. Spud Rider

    Spud Rider Long timer

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    Thank you, OnO. :D The bike handles great without the 10+ pounds hanging high, and rearward on the left side of the bike. :nod After completing the battery relocation, the first think I noticed was the bike was much easier to push around. :wink:
    Yes, your are correct. :nod I need to remove the right side cover to access the fuse box in its current location. Therefore, I need to carry a 10mm socket to remove the bolt on the right side cover. However, the CDI unit is easily accessible, without tools, inside the airbox. :hmmmmm
    My good friend Andy has been a professional diesel mechanic for 30+ years; he warned me my fuse box is currently vulnerable to moisture. :eek1 Andy suggested two options: seal the fuse box to prevent moisture from entering it; or relocate the fuse box under the saddle. I respect his opinion, so I am carefully considering his advice. :nod If the fuse box were placed inside a nice, small electrical box, it could be routed a few inches farther under the fender, and attached to either the frame, or the back of the air box. The fuse box would then be protected from moisture, and it might become more accessible from that location. :nod
    Thank you for warning. :nod I will tug on the battery, and test the integrity of the velcro every time I remove the seat cover. The velcro is inexpensive, so I can easily replace it every year as part of my preventive maintenance. :wink: As another option, I can simply zip tie the battery to the top of the airbox. :nod Movement of the Shorai battery is further restricted by the airbox supports on each side of the frame, the forward wall of the air box intake hole, the wiring in front of the battery, and the battery connectors themselves. :nod

    Spud :wave
    #27
  8. r3r3r

    r3r3r Wildebeast

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    Great thread. Good documentation, Thanks! :clap
    #28
  9. TourPros

    TourPros Local wherever I go

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    Me likey likey:thumb
    #29
  10. Spud Rider

    Spud Rider Long timer

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    You're welcome. :D I have now ridden about 500 miles since I performed my Shorai battery relocation. I am pleased to report the Shorai battery cranks the engine well, and starts my XR650L effortlessly. :nod I am now awaiting arrival of my XR600R, left side cover to complete the job. :D

    [​IMG]

    Spud :wave
    #30
  11. Spud Rider

    Spud Rider Long timer

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    I'm pleased to report my Shorai battery is working great; it cranks the engine hard, and my XR650L starts easily. :nod Several days ago I installed an XR600R, left side cover.

    [​IMG]

    [​IMG]

    [​IMG]

    I now consider my Shorai battery relocation to be complete. :D

    Spud
    #31
  12. ONandOFF

    ONandOFF more off than on

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    :thumbup . :thumbup

    but hey, dontcha think it looks a little skinny now?

    :hide
    #32
  13. Spud Rider

    Spud Rider Long timer

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    :rofl

    I guess you could say I performed "liposuction" on the left "cheek" of the bike, Ono!

    :rofl

    Spud :wave
    #33
  14. Spud Rider

    Spud Rider Long timer

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    Thank you, TourPros. :D

    I am very pleased with the results from my Shorai battery relocation. :thumb I have not had a single problem so far, and I can heartily recommend this modification without reservation. :nod

    [​IMG]

    Spud :wave
    #34
  15. ONandOFF

    ONandOFF more off than on

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    What in the heck has been walking all around in that field in the snow behind the bike? :huh It's not fenced in for livestock...
    #35
  16. Wattner

    Wattner Long timer

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    Cute lil' Thumper Bunnies... Ghees Whaddya new???
    :rofl Just playin' :D
    #36
  17. Spud Rider

    Spud Rider Long timer

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    It's hard to tell, Ono. I think Wattner is probably correct with his bunny rabbit theory, but the tracks could belong to other animals. I frequently see moose, elk, mule deer, whitetail deer, and a multitude of small game everywhere I ride in Idaho. :nod

    [​IMG]

    Spud :wave
    #37
  18. ONandOFF

    ONandOFF more off than on

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    Must be just me... when I saw those tracks, I realized what a large quantity and variety there were, and they seem to wander about aimlessly, some even appearing to stop in mid-track. I'd say judging by the size, mosta the ones we see in the shot were from the fox-coyote-dog-wolf genre, with some deer-elk type thrown in, and who know what those big straight ones on the left are; looks like a person with very close steps walked in there and then got abducted by aliens :lol3
    #38
  19. Spud Rider

    Spud Rider Long timer

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    :eek2

    Perhaps I should keep my eyes on the sky, also! :rofl

    [​IMG]

    Spud :wave
    #39
  20. Spud Rider

    Spud Rider Long timer

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    My Shorai battery continues to work great; I am very pleased with it. :nod Instead of lengthening the wires to the fuse box, I would prefer to find a cap to cover the fuses, and leave the fuse box in its current location. :wink:

    [​IMG]

    Can anyone recommend a suitable cover for the fuse box? The screw holes, and the tabs on the fuse box look like convenient points to attach a cover; if all else fails, I can certainly use zip ties to secure a cover to the fuse box. :nod Perhaps Honda employs this fuse box, with a cover, for another motorcycle?

    Spud :wave
    #40