Posted on 21 June 2015 at 09:17 pm (CET)
This weekend I worked on the quad bike again. I had some issues with the brake system again. Every time after bleeding the brakes the brake pressure was good but a few days later the brake pressure was suddenly much less. I already wasn't satisfied with the brake pressure of this new brake cylinder. Probably because the piston is much smaller than with the original brake cylinder. But I thought that one was broken, so I just wanted to try a different one.
To be sure I tried again with the old brake cylinder and as it turns out it's still working great. I also discovered why I wasn't getting any brake pressure with this brake cylinder last time. I totally missed this one washer that apparently comes with a new banjo bolt with built in brake pressure switch. It has exactly the same color as the banjo bolt.
I placed an extra copper washer between this which made the banjo bolt not thread into the brake cylinder deep enough. Because of this the distance between the piston and the banjo bolt was too big to be able to build up any brake pressure. I removed this washer now so the banjo bolt is threaded deeper into the brake cylinder. While bleeding the brakes I already got brake pressure very quickly now. After the bleeding the brake pressure is also much better than with the smaller Brembo brake cylinder. So for now I'll just keep using the original brake cylinder again.
Since it always took pretty long before I had the quad bike attached on the trailer I bought some new clamping straps. With these I can get it attached on the trailer within 5 minutes. Also placed 2 wheel blocks on the trailer so I can't drive forward too much and damage the bumper while doing so. This nearly happened once. ;) The quad bike is also always exactly in the middle like this.
Now I just still have to wait for the approval test. Meanwhile I do finally have an appointment. The approval test will be in 9 days already, on June 30th. Will have to be there at 8 o'clock in the morning again. It's going to be very exciting again, but I have faith that everything will go just fine this time around. :) I also really hope so cause I finally want to go out on the road and ride it. ;)
Today I made one last modification. At the RDW they said the visors on the headlights are too sharp. They're right about this but it's standard so it probably also got approved like this.
To keep them happy I placed some rubber profiles on it. The sharp edges are gone now and it still looks pretty good.
There's also some good news. I don't have an appointment yet, already trying for 2 weeks but can't seem to get a hold of the one who schedules the appointments. I did still come in contact with the inspector though.
It was still a bit unclear if a seperate EMC test for the whole quad bike would be needed, which normally costs around 1500 euros, or if the certification and test report of the controller would be enough. Thankfully the inspector told me that it won't be needed and that the certification of the controller is enough right now. So the EMC part of the approval is finally done and over with. This was also the hardest part but I won't have to worry about it any longer.
But there's also some bad news, thankfully not for my own quad bike though. At the RDW they're planning to sharpen the regulations for EMC even more. This will already happen very quickly since for my quad bike they discussed if it would still fall under the current regulations. So in the future it'll become even harder to get an electric conversion approved at the RDW. I think an EMC test for the whole vehicle will be mandatory then, or all of the components should be approved. But for my quad bike this is not a problem thankfully.
Now I just have to wait for an appointment, the quad bike is all ready for it again. Hopefully I'll hear something from them this coming week.
This weekend I've made a few modifications so the quad bike will hopefully pass the approval test without any problems soon.
The brake system is completely original again. The footbrake brakes on all of the wheels now. Both brake lines are connected to the brake cylinder now.
The mechanical handbrake is back on it as well.
I've also made a system that gives a warning signal when you get off the quad bike while the drivetrain is still active. I've done this with a switch in the left foot peg.
The drive mode buttons will all 3 flash when you get off.
Since the flash relay I'm using doesn't work well with only LED's I wanted to hide a normal light bulb somewhere which also flashes together with the LED's. But it turned out I couldn't hide this, the light just shines right through the plastic fender. I actually like the effect it gives and it makes it even more clear that the drivetrain is still active.
Since I modified the brake system I wanted to test again. Because it was necessary ofcourse, not because I just wanted to or something like that. :) But in any case the brakes seem to be working just fine.
Made a quick video. Even our dog really likes the quad bike. ;)
Everything that had to be modified for the approval has been done now. There are still a few things where I'm waiting on a reply from the RDW. But hopefully I'll hear something about that this coming week. I'm also looking to make a new appointment already for the approval test.
Posted on 21 May 2015 at 07:44 pm (CET)
Posted on 21 May 2015 at 07:44 pm (CET)
I left early again this morning to go to the RDW for the identity check. Didn't have to drive as long this time, for this check I could just go to the nearest inspection centre.
Had to be there at 8 o'clock and I was even first in line. The spot of the chassis number was inspected and also all of the documents and pictures I took with me.
Thankfully this all turned out good. Normally you'd have to make a new appointment to get the chassis number re-affixed. But I got lucky, the one who's authorized to re-affix chassis numbers was present and also had some extra time. So the chassis number got re-affixed already. :) It was a bit of a search for a suitable spot since the tool they use for it is quite big and apparently doesn't work well on tubes. Thankfully there's one nice flat area on the quad bike, right below the seat. I did have to remove the whole rear fender but the chassis number is on it now. :)
After all this I came home from the RDW again with a good feeling. Just still have to modify a few things now and then I can go back for the approval test. Hopefully it won't take as long this time till I can go there.
Posted on 20 May 2015 at 10:44 pm (CET)
Just a quick update before I go to the RDW tomorrow for the identity check of the frame.
Since the approval test I didn't really do much anymore. I did already start making a system that gives a warning signal when you get off the quad bike and it's still in drive mode. I placed a switch in the left foot peg, looked like the best place to me. With a flash relay I'll just let all of the LED's of the drive mode buttons flash. Should be good enough. But it's still not quite working, need a few more small parts for this.
For the rest I've been busy making the brake system original again since last friday. I had the handbrake attached and also all of the brake lines connected to the brake cylinder of the footbrake. I just couldn't get any brake pressure anymore after that. I've tried everything to bleed the brake system but no luck. So I inspected the brake cylinder but couldn't really notice anything strange.
It could be that the rubbers are just worn out a bit since I still remember when I bleeded the brake system the first time about 2 years ago black brake fluid came out of it. Already thought that was odd but it did still work just fine. Few months ago I bleeded the brake system again and already had a lot less brake pressure, now nothing at all anymore. So I quickly had to buy a new brake cylinder and chose for a better one right away. A Brembo that has once been on a KTM motorcycle. This one works perfectly, bleeding was quite easy again. I just still have the brake system seperated since I don't have a double banjo bolt with the right thread size, will look into this after the identity check of the frame. More important right now is that the brakes are working well again.
For tomorrow I'll just have to wait and see. Hope it'll all go well so I can quickly go back for the approval test again. I'll let you all know how it went tomorrow.