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Step 10Wiring
This part is challenging. Wiring the new 48 v. AC system is complex, plus the original 12V power system is still needed to run the lights, horn, brake lights etc... There are several different ways to proceed:
One: Keep the old and new electrical systems separate, and run the old system off a small rechargable 12V battery. This option keeps the wiring simple, but requires maintenance of two separate battery/charging systems.
Two: Integrate the two systems by using a DC-to-DC converter, which steps down the power from 48V to 12V This is a more complex wiring set-up, but can be maintained with a single charging system, which is much more convenient on a day-to-day basis.
We chose to integrate the two systems together, so we relied on several sources of information to guide us, including the original Honda Rebel service manual, the suggested wiring diagram from the 21 Wheels plans, consultations with the guys at Electric Motorsport and quite a bit of guessing on our part.
It took a few tries, and we burned out some fuses and bulbs along the way. But ultimately we got the wiring working reliably.
One: Keep the old and new electrical systems separate, and run the old system off a small rechargable 12V battery. This option keeps the wiring simple, but requires maintenance of two separate battery/charging systems.
Two: Integrate the two systems by using a DC-to-DC converter, which steps down the power from 48V to 12V This is a more complex wiring set-up, but can be maintained with a single charging system, which is much more convenient on a day-to-day basis.
We chose to integrate the two systems together, so we relied on several sources of information to guide us, including the original Honda Rebel service manual, the suggested wiring diagram from the 21 Wheels plans, consultations with the guys at Electric Motorsport and quite a bit of guessing on our part.
It took a few tries, and we burned out some fuses and bulbs along the way. But ultimately we got the wiring working reliably.
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