I'm really enjoying this, a good read. If this bike is going to be a rider and not a concours show bike you might consider using modern plugs and connectors when rewiring rather than those dreadful bullet connectors. I did this twenty years ago on my bike and haven't had an electrical problem since. I'd also suggest soldering any wires feeding the Boyer rather than crimping as voltage drop will give strange symptoms and a sore ankle if it kicks back. I've just started working on a 1963 Matchless which has been sitting in boxes in my basement for years.
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