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Hibb5337
27th November 2009, 15:13
Hey all....My name is Brian and i'm pretty new to the forums. I've been on looking into threads, but haven't piped up much. After having my 1200N for about a year and a half now, I decided that this winter was the time to get some big stuff done. I followed Cosmo's thread and loved the outcome of the rewire he did. I've been wanting to get rid of that wire bundle along the frame for a while now and this was my motivation. I've been speaking with Jeremy about this project and trying to get some ideas and tips from him. I'll start posting some pics of the progress as I go. I do have the bike down to the frame as of now with the front end still on it. Going to start getting it cleaned up and drilled out for the rewire. The end product Jeremy ended up with was absolutely amazing during his Nightster transformation. I don't think mine will be that exciting but I figured I could share it with a bunch of people who love this stuff. Feel free to throw some tips, comments, and criticisms my way...

Before breakdown.....

http://i784.photobucket.com/albums/yy129/bhibbert/P6020042.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PB260007.jpg

Now......

http://i784.photobucket.com/albums/yy129/bhibbert/PB270037.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PB270038.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PB270039.jpg

Charles:
27th November 2009, 17:49
You know...since you have it down to the frame, you might as well hardtail it.

:)

Hibb5337
27th November 2009, 17:51
i do like the idea.....i'd love to do struts and a solo spring seat.....wife might hate me if i got rid of the 2 up seat though....hahaha

Cosmo Kramer
27th November 2009, 18:27
http://i784.photobucket.com/albums/yy129/bhibbert/PB270039.jpg

:clap....got the motor out!

I'm working now....:shhhh....but I'll post on here later tonight some of my ideas / issues I had with my rewiring job. Looking good though!

Oh....and of course...Welcome to the XLForum from Buffalo, NY! Glad to have ya with us.

Bob F
27th November 2009, 19:19
I see it's your first post. Hello from Pittsburgh and welcome to the XLForum.


Now would be a good time to change the color of your frame. Wouldn't take long to pull the front end.

Pork Chop
27th November 2009, 19:28
Welcome to the forum from Savannah Georgia!

24inchapes
27th November 2009, 20:01
Would NOT hardtail it, your back and ass will send you hate mail in a few years.

klinesamuel
28th November 2009, 01:47
I am very impressed by what you have done so far. I have been thinking about yanking my motor and everything else and powder coating the frame something other than black.

Sam in York

Cosmo Kramer
28th November 2009, 02:01
Just some background to everyone else so they don't think I am hijacking this thread, Hipp asked me for some of my thoughts and ideas on rewiring his bike. While he might not think this is going to be as exciting as mine...I think the opposite is true. I suggested he started a thread so we could all throw out or ideas in one place. I think together with everyone we can improve on what I did and I am looking forward to watching his progress. Hopefully this will inspire others to tackle something like this.

With that being said...here are some general thoughts/ideas before we get too deep into the actual rewiring:

1). Service Manuals - At a minimum you need the Factory Service Manual (it does have the wiring schematics included) but I highly recommend the Electrical Diagnostic Manual as it has some great electrical trouble-shooting diagrams and better descriptions of what all the electrical components do.

2). Voltmeter - Need a cheap one ($10-15 from Autozone) to check continuity between connectors after you have splice your new wires in. I highly recommend going through all the wires that go to ground, all the connectors and the ECM to make sure don't miss anything or wire something wrong at the very end before putting power to the system. I did this and found I missed a ground wire going to the fuel pump.

3). Soldering - I bought a soldering iron but halfway through I ditched it for a propane torch which heated the wire in about 1/10th the time. It does take a little more practice to master it but once you get rolling it makes it a lot easier / faster. Also need to know how to solder. I did a write-up a while back for someone during the middle of my build. Some fellow members agreed with my technique and I have had no problems with any of my splices over the last summer and 5k miles:

http://xlforum.net/vbportal/forums/showthread.php?t=481118&highlight=western+style+soldering

It is very important when cutting the wires at the connectors to leave as much of the stock wire as possible....you can always cut it back but you don't want to run out of wire when you strip it and try to solder it to your new wire. Also, when you do get to the point that you are ready to solder, you want to stagger your splices so there is no big klump because the splice/solder/shrink wrap will be almost twice the diameter of the wire.

4). Existing connectors - what is needed and what do you want to leave out? My thoughts....I kept all of them. I want to be able to remove my handlebars, gas tank and motor in the future without cutting the wires that I just ran. I did relocate all the connectors to positions on the bike that I wanted versus where they were stock.

5). Need to develop an overall game plan before starting. From our earlier conversations, Hipp's main goal (and please correct me if I am wrong here) is to get rid of all the wiring along the backbone and downtube, run the wires for his controls on the handlebars internal, leave the ECM in its current position in the rear fender and possibly move the fuseblocks under the seat.

Hibb5337
28th November 2009, 07:51
First off, Thanks everybody for the welcomes... I'm pretty stoked about starting this project and I'll try and move at a good pace, but one reason I started now is so I can take my time and do everything right.

Cosmo is right on in that my major goal is just to hide the wiring on the bars and along the backbone and downtube. There are other plans of painting some misc parts of the motor, possibly changing to struts and a solo spring seat, but the wife isn't too happy with that idea. My immediate plan is to grab the manuals I need in the next few days, start mapping out the wiring harness and finding out exactly where everything will enter and exit the frame. as for the tools and what not, i'm pretty sure i have everything....ha, i just soldered something the other day and realized i'm about out, so i'll have to stop and grab some. other than that, i'm gonna have to grab some new drill bits (good ones) and a bunch of heat shrink. i'm sure there are a ton of things of things i'm forgetting, but i'll grab them along the way as i need them. the damn nickel and dime stuff!!!!

jharback
28th November 2009, 08:29
First off, welcome to the forum. This should be an interesting thread to follow. I would also consider painting/powder coating the frame while you've got it stripped down. Maybe a flat gray to match the engine covers? I would certainly think seriously about doing something to make it different from all the other bikes out there.

ElectricCityIron
28th November 2009, 18:15
Welcome from the Electric City...

Gluck man.

Remember, if you keep everything organized the job will go alot smoother...
have fun too...:banana

Cosmo Kramer
28th November 2009, 18:22
There are other plans of painting some misc parts of the motor, possibly changing to struts and a solo spring seat, but the wife isn't too happy with that idea.

Hibb, why not have your cake and eat it too? Swapping between struts/shocks is probably a 20 min deal. What about getting the solo seat (you should relocate the ECM...which is why I want to bring this up now) and when your wife wants to ride....I bet you could swap it over to a 2-up deal with the seat you have now and shocks in 30 minutes? How often does she ride with you? I wouldn't want to be doing that every other time I go riding....but if it is every now and again.....well, it is something to think about before you get started.

Mister O
28th November 2009, 19:36
subscribed

Hibb5337
28th November 2009, 19:38
thats not such a bad idea. when we were talking earlier about the Tamarack Drop kit, i'd take those blocks off when she wanted to ride and slap em back on afterwards.. didn't take more than 20 minutes. i do like the low look ALOT better. i like the way the fender follows the tire when its lowered. i do like your thought though.

today i made a little progress with the handlebers... they had a few scratches on them from windshield mounts. I tried out a buddys windshield on a road trip and hated it. plus, i scratched my bars installing it... so, i drilled out the holes for the wires today on the bars, got it re-painted and spent about 2 hours trying to take a molex connector apart. i finally found a youtube video showing an easy way to do it, and after that had it disco'd pretty quick. heading to work now, but i'll get some pics up tonight of the progress so far. pretty slow like i said, but my days off are monday and tuesday, so i'm gonna try and hit it hard then.

Tike71
28th November 2009, 22:12
Link to said youtube video?
I couldn't figure out how to remove the wires from the connectors either.

Edit: Nvm i found the video

Hibb5337
28th November 2009, 22:40
cool....sorry bout the delay, at work now. yeah, it was a video of a guy with artimus shirt on....step by step...very easy after that.

Hibb5337
28th November 2009, 22:59
I would also consider painting/powder coating the frame while you've got it stripped down. Maybe a flat gray to match the engine covers? I would certainly think seriously about doing something to make it different from all the other bikes out there.


I like this idea alot.....I do like the look of the black frame, but this would def. stand out as being different than most. I'm taking my fender to get re-painted soon and some parts off of the motor for powdercoat....i'll make sure and ask the dude doing it how much it would be to do the frame.

Cosmo Kramer
29th November 2009, 00:16
spent about 2 hours trying to take a molex connector apart.

Hibb....where are you going to have your connectors when it is all said and done? I would recommmend behind the headlight or even better yet above the headlight and below the visor. If you do this....you are gonna have extra wire if you try and just reuse the stock wire since they sit under the gas tank. I guess what I am getting at is that I didn't bother taking any connectors apart....just cut and splice in front of them.

Hibb5337
29th November 2009, 00:56
Funny u ask. I was thinking about that as I'm trying to map out everything and where connectors will fall. I was going to try to keep splicing to a minimum but I don't want extra wire bunched up everywhere either. Did u add wire to the main harness side for the bars? If I recall, they connected under the tank.

Cosmo Kramer
29th November 2009, 01:12
Funny u ask. I was thinking about that as I'm trying to map out everything and where connectors will fall. I was going to try to keep splicing to a minimum but I don't want extra wire bunched up everywhere either. Did u add wire to the main harness side for the bars? If I recall, they connected under the tank.

Most of the wire on my bike is brand new. The only stock wire I saved was to the O2 sensors and a few others here and there that were long enough. But for the most part...I cut everything free and started from scratch except for splicing back into the connectors. It was still good to label everything to see what spliced into what and where the wire stepped up in wire size gauge wise. My connectors are hidden inside my nacelle....so I cut the wires from the switch housings about 6-8 inches down so that the splices would be staggered and inside the handlebars and then I just spliced back into the
stock connectors once I exited the handlebars and determined the length I wanted.

A couple things you want to do to any hole you drill is to take file or a dremel and remove the sharp edges of the hole. Also, I couldn't find this anywhere except for the pieces I cut off the original wiring harness....but make sure you put a protective sleeve over the wires where they go through the holes. You can see the sleeve in this first shot:

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_0665.jpg

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_0687.jpg

Hibb5337
29th November 2009, 02:38
i'm not certain what i'll do as of yet as far as cutting wires.....i know i'll have to make alot of cuts, but i'm going to try and map everything out the best i can before i hack that harness apart.

Hibb5337
29th November 2009, 02:39
does that nacelle have a lot of room to hide connectors? i'm just curious if the visor will have enough space to hide connectors

_Feral_
29th November 2009, 03:32
I really love the look of the internally wired bike. I WANT to do this project, but I really don't want to have to strip the bike all the way down for it.

I may take the lazy man's way out and just attempt a wire tuck without a tank lift when I relocate the ignition coil.

Or is it possible to do this keeping the stock wires and just removing the tank?

Cosmo Kramer
29th November 2009, 04:26
does that nacelle have a lot of room to hide connectors? i'm just curious if the visor will have enough space to hide connectors

Yeah....quite a bit of room...cause I even hid all my HID headlight components in it also. As far as under the visor...now that you have everything apart I would just take the connectors and see if you can physically get them inbetween....will be tight for sure. If nothing else...stick the grey connector and the larger black one....hide as much as you can.

I really love the look of the internally wired bike. I WANT to do this project, but I really don't want to have to strip the bike all the way down for it.

I may take the lazy man's way out and just attempt a wire tuck without a tank lift when I relocate the ignition coil.

Or is it possible to do this keeping the stock wires and just removing the tank?

Feral....one thing Hibb and I discussed was if he needed to pull the motor or not. I pulled mine for two reasons...because all the wires going to the air/fuel management system (injectors, sensors, fuel pump) come out of the bottom of the backbone just above the air intake tubes/fuel injector area between to the cylinders and all my wires going to my relocated ECM come out at the end of the downtube just above the rear motor mount. Can't drill those holes without pulling the motor.

The idea I had of not pulling the motor is to pull the gas tank off and drill holes in the backbone that are parallel to the floor...pull the wires through there and then down to the sensors and etc. The only thing is that you where I drilled two holes above the engine it may take 3 or 4 because there is limited room between the gas tank and backone where the wires would have to exit the frame and turn down. At the tail end....drill a larger hole just above the battery to have all the wires come out of the backbone/downtube there.

Just a thought.

Cosmo Kramer
29th November 2009, 07:25
Hibb....Do you plan on keeping the horn in the stock location? I moved mine to where the rear brake master cylinder is mount under the swingarm. Just didn't like the location of it stock as I thought it was an eye sore and was part of my clean up. Also...did you say you were going to relocate the coil? Also, what about the ignition switch? If you are not...I will have to modify what I list below.

Anyways...here is some more info that will hopefully help. I am going to list a few points where I drilled the backbone and what wires exited there. I am going to just refer to the connector that you will see in the wiring schematic when you get the manual and not each individual wire:

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/Frame.jpg

Point A: (there are holes on both sides of the frame): "Right hand controls", "left hand controls", "front turn signals", "headlamp" and "instruments and indicator lamps".

Point B: "Fuel pump and sender assembly", "ignition coil", "rear injector", "front injector", "idle air control", "intake air temp / manifold absolute pressure sensor" and "throttle position sensor".

Point C: "Engine temperature sensor"

I ran the following wires under the engine on the exhaust side. I actually ran the wires behind the sprocket cover and then up front....you can see the black wire bundle in the next two pics.

By the rear pivot bolt / sprocket cover:
http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_0924.jpg

By the front engine mount bolt:
http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_1003.jpg

Wires bundle under engine: "Front O2 sensor", "crank position sensor", "horn (if you leave it in the stock location)", "neutral switch" and "voltage regulator"

Here is a close-up of where the "Point A" holes are and how it looks with the wires coming out:

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_0672.jpg

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_0765.jpg

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/100_0767.jpg

BMXATV
29th November 2009, 16:35
this is an insanely huge undertaking. kudos cosmo for taking the first run at it. hibb....kudos for taking the leap. i'll be watching the progress as well. i like cosmos idea about the part time strut/spring seat setup when she's not ridin with you. for going through all of this i think you deserve a little piece of cake too.

Hibb5337
29th November 2009, 18:26
Okay....So i got the handlebars are wired up today. Wasn't too bad. I just took my time like everyone said, kept the protective factory shield over the wires, used weed eater wire to feed it through, and it worked perfect. I used masking tape to tape the weed eater wire to the bundles as i pulled them through.. Couldn't find any packaging tape, but it worked fine. also, i apologize for the crappy pics, i need to get the lighting fixed in the garage..ballast took a crap in the shop lights above the bench.

here are the bars repainted and drilled
http://i784.photobucket.com/albums/yy129/bhibbert/PB290043.jpg

I have written down diagrams of the connectors and the where the wires go into them to make re-assembly much easier. i also tagged and bagged connectors and related parts so i don't get things mixed up
http://i784.photobucket.com/albums/yy129/bhibbert/PB290045.jpg

feeding bundle through with weed eater string.
http://i784.photobucket.com/albums/yy129/bhibbert/PB290046.jpg

http://i784.photobucket.com/albums/yy129/bhibbert/PB290051.jpg

http://i784.photobucket.com/albums/yy129/bhibbert/PB290053.jpg

http://i784.photobucket.com/albums/yy129/bhibbert/PB290057.jpg

Hibb5337
29th November 2009, 18:36
now.......i tried something with the stock speedo clamp and i'm pretty sure i freakin hate it!!! hahaha....looks like my bike has little horns. the whole purpose was try and retain the dummy lights up at the stock location without having to buy an aftermarket clamp. well, looks like i'm going to have to buy one...oh well, i know FISHBOY makes some good ones. anyway, i thought i could cut the speedo ring off of the clamp and make the stock clamp flat at the top. the way it is made, this would have left the front of the clamp wide open and looked weird in my opinion. I might keep trying to see if i can get some nice even points with the stock clamp, but ..........actually, no.....i hate it...hahaha...everyone take a look though. i'd say i failed!!:doh:o

http://i784.photobucket.com/albums/yy129/bhibbert/PB290061.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PB290062.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PB290063.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PB290064.jpg

Hibb5337
29th November 2009, 18:42
I really love the look of the internally wired bike. I WANT to do this project, but I really don't want to have to strip the bike all the way down for it.

I may take the lazy man's way out and just attempt a wire tuck without a tank lift when I relocate the ignition coil.

Or is it possible to do this keeping the stock wires and just removing the tank?

I hear ya man...... I thought about it and thought about it, and finally after seeing Cosmos thread, decided screw it!! Its winter, now is as good as time as ever to start a huge project. And the good thing is, I have plenty of time to finish, so I can take my time and do it right. I couldn't believe how quickly the bike actually breaks down....Doesn't take long at all. This is a huge learning lesson for me as well. I'm a jet mechanic by trade, and just finished at Purdue with an Aviation Tech/Eng degree, but i've never worked on motorcycles. I guess maintenance is maintenance.....be it cars, aircraft, or motorcycles....thats the way i was looking at it.

Hibb5337
29th November 2009, 18:47
Hibb....Do you plan on keeping the horn in the stock location? Also...did you say you were going to relocate the coil? Also, what about the ignition switch?

Cosmo, I didn't even think about the horn until you mentioned it. it does just sorta stick out where it is. I'm sure i'll find another place for it. As for the coil and ignition switch, they are both being relocated yes. The coil is going to the left side of the motor, and i'm still not sure about the switch. I dig the area that you relocated yours to, but I don't want to copy everything you do! hahaha. i've been trying to come up with a place for it, but haven't thought about it too hard yet.

BMXATV
29th November 2009, 20:09
I hear ya man...... I thought about it and thought about it, and finally after seeing Cosmos thread, decided screw it!! Its winter, now is as good as time as ever to start a huge project. And the good thing is, I have plenty of time to finish, so I can take my time and do it right. I couldn't believe how quickly the bike actually breaks down....Doesn't take long at all. This is a huge learning lesson for me as well. I'm a jet mechanic by trade, and just finished at Purdue with an Aviation Tech/Eng degree, but i've never worked on motorcycles. I guess maintenance is maintenance.....be it cars, aircraft, or motorcycles....thats the way i was looking at it.

jet mechanic by trade.......that explains everything.

Hibb5337
29th November 2009, 20:19
jet mechanic by trade.......that explains everything.

hahaha....i don't know if thats a bad thing or not!

Cosmo Kramer
29th November 2009, 23:56
Okay....So i got the handlebars are wired up today. Wasn't too bad.

I was gonna recommend starting on the handlebars as it is a good / easy way to get your feet wet. Came out great!...well done!...although those wires coming out of the handlebars look pretty long! ;)

Funny...I thought about cutting up my N top clamp like you did....well not leaving the devil horns. But the way it is cast I didn't like the look of the back being open. If you like the indicator strip there....you can think about going the way I did and use the top clamp off of a Custom model. You will have to get a new indicator strip though.....$53.

Hibb5337
30th November 2009, 01:03
i might stop by the dealer tomorrow and see about the custom clamps...how much did that puppy run ya?

Cosmo Kramer
30th November 2009, 02:03
i might stop by the dealer tomorrow and see about the custom clamps...how much did that puppy run ya?

I bought a complete riser set-up off of a 2003 custom...I think I paid like $70-80 for the entire package. I know on the 07' customs the speedo housing ring is built into the top clamp (similiar to the Nightster ring that you cut....but it is next to the gas tank and not above the headlight visor)...I am not sure what year they started that. Hopefully somebody can provide a part number for you for just the top clamp.

09 blackthunder
30th November 2009, 07:55
This so exciting and fun to watch. I will do this to my nightster eventually. Maybe when i get all my front end, risers, and bars for my nightster Fat Bob conversion that i'm doing right now.

Gone
30th November 2009, 08:29
Wow - I'd be real scared doing what you have done, with the huge strip down. I have new stainless clutch, throttle and brake cables to fit over the Christmas period and that will be traumatic enough for me.

Good luck and welcome to the board.

_Feral_
30th November 2009, 08:37
I'm a jet mechanic by trade, and just finished at Purdue with an Aviation Tech/Eng degree, but i've never worked on motorcycles. I guess maintenance is maintenance.....be it cars, aircraft, or motorcycles....thats the way i was looking at it.

Hahahaha... I'm a soldier.:p

I'm still considering it myself but I don't want to have to take the motor out. I'll have to have a look and decide if I'll do it or not. Winter or no, the bike is my primary source of transportation. My truck tags expired in April when I was in afghanistan and I haven't gotten it reregistered yet.:frownthre

Hibb5337
30th November 2009, 17:47
well.....started drilling on the frame today. here comes the nickel and dime stuff. batteries in the cordless don't last ten five minutes anymore. got a corded drill and some new bits...smoked the bits within the first hole on the backbone up by the front end. time to go spend the money on a good bit i guess...haha. my garage is complete chaos right now... parts of bike everywhere.... i'll get some progress pics up soon, but heres what it looks like in the mean time.:censor:censor:censor

insane......rubber up!!!! i couldn't get the frame secured to the jack well enough to be pushing on it and drilling on it, so i turned it upside down for the rest of the drilling
http://i784.photobucket.com/albums/yy129/bhibbert/PB300065.jpg

you can see the two holes on the bottom of the backbone here and where i removed the bracket.
http://i784.photobucket.com/albums/yy129/bhibbert/PB300066.jpg

Cosmo Kramer
30th November 2009, 18:45
...smoked the bits within the first hole on the backbone up by the front end.


Yeah....you are cutting a lot of metal there....probably around 5/16" thick. Make sure to dip the drill tips in some oil every now and then...that helps. Sorry I was late with the tip....but I smoked one GOOD bit doing mine....so I think you were SOL anyways.

Looking good! :clap

09 blackthunder
30th November 2009, 19:00
Hibb you using a center punch to help with your drilling points? It's helps. Justa pointer and the oil on the bits like Cosmo said

Hibb5337
30th November 2009, 20:37
haha...yeah, center punch, stepped the drill bits, used oil and smoked four bits.....crap! ah well, i may have been a little late with the oil. I took a different approach with the holes at the front end. i drilled a bigger hole on top of the backbone under where the tank will sit. since there is about a 3/8" gap between the tank and backbone, my front end wire bundles will come out here, separate, and go around the frame... i think it'll work out fine. now just gotta get the "half hole" filled in and painted. i could NOT get that thing drilled out.. maybe i have the only nightster in the world with a Tungsten frame...:) ha.

anyways, here is where i'm at..... gonna start mapping out wiring and diving into that next.

this is the bottom of the downtube..
http://i784.photobucket.com/albums/yy129/bhibbert/PB300068.jpg
this is on the back of the downtube..
http://i784.photobucket.com/albums/yy129/bhibbert/PB300071.jpg
this is where the front end bundles will exit under the tank.
http://i784.photobucket.com/albums/yy129/bhibbert/PB300072.jpg

Charles:
1st December 2009, 01:47
now.......i tried something with the stock speedo clamp and i'm pretty sure i freakin hate it!!! hahaha....looks like my bike has little horns. the whole purpose was try and retain the dummy lights up at the stock location without having to buy an aftermarket clamp. well, looks like i'm going to have to buy one...oh well, i know FISHBOY makes some good ones. anyway, i thought i could cut the speedo ring off of the clamp and make the stock clamp flat at the top. the way it is made, this would have left the front of the clamp wide open and looked weird in my opinion. I might keep trying to see if i can get some nice even points with the stock clamp, but ..........actually, no.....i hate it...hahaha...everyone take a look though. i'd say i failed!!:doh:o

http://i784.photobucket.com/albums/yy129/bhibbert/PB290061.jpg

Just cut the rest of the "horns" off, then grind them down smooth and repaint.

Cosmo Kramer
1st December 2009, 03:47
this is on the back of the downtube..
http://i784.photobucket.com/albums/yy129/bhibbert/PB300071.jpg


Hibb....how big did you make that hole? When I was wiring up my fuseblock for some reason I had wires running outside and down and figured that defeated the purpose of the entire project, so I drilled a 2nd hole towards the oil tank side of the downtube for the wires going from the fuse block to the ecm and other related sensors around the rear cylinder.

Anyways....you are making really good progress. Just a word of warning....when you start tackling the wiring...it took me a LOT longer than I expected.

Here is a pic kinda showing what I did for my wiring to and from the fuse block. You can see the zip ties around the frame where there blue and red arrows are showing the wires going to and from the fuse blocks. Like I mentioned to you in the PM....I made a metal template in the shape of that portion of the upper frame so that I could hold the wires up and away from the oil tank. It is also wrapped in a heat protection sleeve just for added measure. Where the wires make the 120 degree or so turn towards the center of the bike...back in that corner is where I put the "Fuel Sender Resistor Assembly". On the opposite side of the bike...if you look at the profile of the oil tank you'll see there is a shelf under the frame.....that i where the turn signal / running / brake light module is.

http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/FuseWiring.jpg

_Feral_
1st December 2009, 05:43
Well, I pussed out. Just finished my wire tuck. Pics to follow (once I get my coil remounted).

Hibb5337
2nd December 2009, 16:01
i think im about a 1/4 of the way done with the wiring.....holy crap there's a lot of wires on this bike. I had most of the bike wired and ran internally from the downtube back, but i had trouble feeding all the wires down from the front so i pulled everything out, and i'm gonna start again.......grrrrrrrrrrrrrr.... All in all, it's getting a lot clearer on what can be routed where. making sure everything fits right and goes in smooth is taking some time, but i think it'll be worth it after im done. my weekend is over, so back to work today. i'll get some work done here and there over the week, but no major stuff until monday..:frownthre
man i hate work! i'll post up some pics when i start making some headway again.

tnt0303
5th December 2009, 02:16
take your time and do a good job. no reason to get worked up . that makes things worse.

Hibb5337
5th December 2009, 03:14
yeah...not going to get in a rush.....thats why i ripped it all out again. wasn't fitting right. i've already gone through 100' of wire....haha...obviously ran alot of extra to have slack but holy crap....didn't think i'd use it all!!

Hibb5337
8th December 2009, 23:22
Sorry for the delay, but again, trying to take my time with this project plus I've been pretty busy with work. All of the internal wiring is now done, and starting to reconnect everything now. Got the motor back in and making progress, but Cosmo was right. The wiring part takes so much time to get everything in the right place, terminated, routed, and soldered back together. As far as cosmetics, i'm still going to take some covers off and have them powdercoated sometime, but i'm in no hurry as the riding season is pretty much over. (sleeting right now) been thinking about changing the rear fender, seat, etc as well. just can't decide on what route i wanna go with. also, can't figure out where i want to put the ignition. trying to find a spot that's different, but having a hard time coming up with a good spot. here are some current pics.

the biggest mess last week
http://i784.photobucket.com/albums/yy129/bhibbert/PC010069.jpg

as of today....getting there
http://i784.photobucket.com/albums/yy129/bhibbert/PC080070.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PC080071.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PC080072.jpg

Cosmo Kramer
9th December 2009, 00:04
:banana:banana:banadanc:banana:banana

Lookin' good Hibb!....lookin' good! Man...that brings back fond memories looking at those unterminated ends....remember thinking....."Wow....I'm not even close to being done!!!" :laugh

Looks like you are keeping the ECM in the stock location?

Hibb5337
9th December 2009, 00:36
i was going to move it to the side of the battery like you had. one question, i forgot to ask a while back....how did you get the wiring to and from the fuse block to be so nice and neat??? i didn't cut the wires at the fuse blocks, and not sure if you did either, but i think i remember you saying you did. I tied together what i could and bundled up some wires under there, but couldn't get it as clean as i'd like.

Cosmo Kramer
9th December 2009, 01:04
one question, i forgot to ask a while back....how did you get the wiring to and from the fuse block to be so nice and neat??? i didn't cut the wires at the fuse blocks, and not sure if you did either, but i think i remember you saying you did.

Yeah, I cut loose both my fuse blocks and ECM connector and ran new wires up to everything. I went through quite a bit of wire. I didn't want to be constrained by the factory wire lengths or routing. I figured if I was going this far....I might as well make it exactly the way I wanted. Really the only stock wires on my bike are at the connectors....the rest is brand new that I ran.

I still have some clean-up to do under the seat with the fuse blocks and wires....but it isn't anything that needs to be done right away.

Bulpitt
9th December 2009, 01:10
Just want to keep tab's on this thread, you guys are CRAZY. I love it!!!!

Hibb5337
9th December 2009, 05:21
Cosmo.....I don't know how you did it, but i'm basically done with the wiring and cannot for the life of me get the ECM to fit on the side of the battery. Its fits nice right beside it, but i can't get the cover on over it.. Unfortunately, that's the spot I routed the wires for....dunno if I can fit it anywhere else. did you modify where the battery sits by any chance??

Hibb5337
9th December 2009, 05:41
********EDIT**********

Just saw your thread on modifying the ECM and battery tray. You my friend are a genious...hahaha....i'll give it a whirl!!!

Cosmo Kramer
9th December 2009, 12:12
********EDIT**********

Just saw your thread on modifying the ECM and battery tray. You my friend are a genious...hahaha....i'll give it a whirl!!!

:laugh...I just copied the link to reply to your earlier post....but I'll put it on here too just in case others are looking for it:

http://xlforum.net/vbportal/forums/showthread.php?t=482796

Hibb5337
14th December 2009, 02:13
got the bike back together and fired her up..everything works!! haha....i'll get some progress pics soon...going to stop by HD dealer tomorrow and order coil mount....tried to make my own but don't like the way it turned out. love the way all the wires are hidden now......i also think i might go ahead and get a nacelle on order....watching one on ebay now....just a bunch of wires to hide behind headlight and really no way to fit em all back there...:)

Cosmo Kramer
14th December 2009, 06:40
got the bike back together and fired her up..everything works!! haha....i'll get some progress pics soon...going to stop by HD dealer tomorrow and order coil mount....tried to make my own but don't like the way it turned out. love the way all the wires are hidden now......i also think i might go ahead and get a nacelle on order....watching one on ebay now....just a bunch of wires to hide behind headlight and really no way to fit em all back there...:)

:clap Congrats Hibb!! Great feeling when she fires up after all that isn't it??

Definitely need to take some pics of your ECM relocation....did you mod the battery tray?

maximummaxime
14th December 2009, 07:36
you guys are doing one outstanding job thanks for all the details.

in the wind
14th December 2009, 07:59
all this chopping / cutting etc.-- i can not wait to get mine on the jack for this winters mods.

Hibb5337
14th December 2009, 20:13
Definitely need to take some pics of your ECM relocation....did you mod the battery tray?

I cut the ECM to make it fit better.....i didn't cut the battery tray yet, i'll probably try that today. just have to find a way to strap the battery in similar to yours....i'm about 1/8" off as well at this point for getting the cover closed.

Hibb5337
22nd December 2009, 07:24
getting closer to being done....besides powdercoating some covers and cosmetic changes. trying to find a speedo (broke the glass on mine) and going to get new clamp for handlebars. have to finish and paint the L bracket that connects the coil to the motor mount. So far I love the look of all the hidden wires. sorry for the horrible quality. lighting in the garage is terrible.

http://i784.photobucket.com/albums/yy129/bhibbert/PC220073.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PC220074.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PC220076.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PC220078.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/PC220080.jpg

Cosmo Kramer
22nd December 2009, 13:36
Looks good Hibb! Well done! One question and one request from ya. The question is what are the wires that are running up between your cylinders on the coil side of the bike?...are those going to the coil?

My request is for some more shots of your ECM relocation...can you get a pic from as if you were standing closer to the front of the bike as opposed to straight to the side and one of under the seat as I assume that is where you put the fuse blocks. I would like to add your work to my ECM relocation options thread. Thanks!

Again...nice job! Rep for ya!

Hibb5337
24th December 2009, 23:13
hey Cosmo......yep, those are the wires for the coil. I'm not sure if i like the fact that they're visible, but I forgot to run them through the backbone....DOH!!!! i'll get some more pics of the ECM relocation for you as well. I am struggling to find a Nacelle as well. The mess of wires behind the headlight is driving me nuts. Good thing I have about 3 mos before I can ride it. I'll get one on order soon if I can't find one on eBay.

Cosmo Kramer
29th December 2009, 05:12
Hibb...what about running the wires for the coil under the gas tank instead?...and just bring them down with the wires that come out from the backbone.

Now that you have gone through this....any suggestions / ideas for the next person that does this that come to mind?

ozracer
1st January 2010, 04:11
Hi guys first post from down under doing research whilst waiting for my iron 883 to be delivered.

My question is the wiring for the headlight and handle bars couldn't you have made it a bit cleaner by drilling a hole at the very front of the stem and taking the wiring out through the front of the bike instead of exiting out on the side below the tank.? I presume the internals of the stem are clear of obstruction I am not sure because I have never dissasembled one I am just presuming the front stem is for bearings to support the front forks?

Hibb5337
1st January 2010, 04:47
arrrrrggggghhhhhh......sorry about long delay in trying to get pictures up.... i've been crazy busy with work and hardly home except to sleep! cosmo, i'll get some pics up asap of the ECM for your thread. as far as running the wires under the tank, i might try that. i'll have to add some more length to them to bring them up the downtube, under the tank and have them exit with the others.


ozracer......as far as cutting hole in the front of the neck, i believe there is a stem inside there that pivots back and forth......someone correct me if i am wrong, and sorry. couldn't think of better word than "stem".........after looking in manual, it actually IS called a stem...haha. anyway, yeah, this part i'm pointing to in picture would be in the way if you tried drilling through neck

http://i784.photobucket.com/albums/yy129/bhibbert/viewphp.jpg

ozracer
1st January 2010, 06:41
Thats answers that then Hib thanks by the way great project.

Hibb5337
1st January 2010, 06:56
no problem man...and welcome to the forums. congrats on the iron! post some pics up of that when u get it. also, this project stemmed from Cosmo Kramers transformation of his bike. His bike is where i got the motivation and he did an incredible job on his N. also, there are a ton of people on here that give great support and info whenever u have a question so post away.

Hibb5337
1st January 2010, 07:07
Cosmo asked if I had any suggestions for people that were also thinking of doing this sort of tear down for hiding wires. The one big thing I would suggest is prepare yourself for the insane amount of time that goes into rewiring the bike. Tearing it down is literally as easy as taking pictures, marking where certain things go, organizing parts as them come off and labeling them as well. Tear down and reassembly was absolutely a breeze, but the wiring is an in depth project. You will definitely need manuals, and the wiring essentials. (voltmeter, soldering tools, LOTS of wire, etc.) .....and patience. I still have a long way to go even though the bike is basically back together and running. I'm going to change the route of certain wires that are currently exposed. Along the lines of suggestions pertaining to this project, I would say to set aside a LOT of time for this. Obviously this is not a project that could be completed in a weekend. Well, I guess it could be if you were crazy ambitious and an absolute pro, but for most of us, we mess around on our days off and whenever else we get a chance. So far, my best resource has been other members on the site with great info, pics, and suggestions during this project. Good luck to anyone who goes this route. Its a challenge, but it's pretty damn fun and looks cool too!!

ozracer
2nd January 2010, 14:47
Hibb keep up the motivation you are doing a great job....

On another note I stumbled across this link whilst researching this stuff copy the link below into your browser

http://www.motogadgetshop.com/product_info.php/info/p484_m-Unit.html/XTCsid/55d2d0171ba0782487508d41cf97074d

This is a digital control unit for motorcycles that completely deletes the fuse box and relays and operates all your electrical equipment digitally. I suspect you could actually eliminate a vast amount of the stock wiring with this set up and clean the look up inside the frame considerably. have a look around at their products they make some impressive electronic gadgets for bikes.
Its a pity cosmo didnt do this because he virtually has a complete new loom..

Cheers,

Adam - Australia.

Hibb5337
5th January 2010, 04:53
FINALLY GOT A NACELLE!!!!!!!!!!!! YEAH!!!! been searching and making offers on one forever!!! some dude wants 500 BUCKS for one on eBay and won't accept reasonable offers. I got outbid at 210.00 yesterday for one and finally found one today for 100 bucks!!! pays to be patient i guess. I'm stoked to get the nacelle in, painted and mounted to hide that wiring mess.




On another note I stumbled across this link whilst researching this stuff copy the link below into your browser

http://www.motogadgetshop.com/product_info.php/info/p484_m-Unit.html/XTCsid/55d2d0171ba0782487508d41cf97074d


I love this motogadget stuff!!! I'm leaning towards the motoscope mini right now // i light the one that sits flush in the handlebar clamp....really pricey, but I think it'll be worth it.

Cosmo Kramer
7th January 2010, 03:07
Tear down and reassembly was absolutely a breeze, but the wiring is an in depth project. You will definitely need manuals, and the wiring essentials. (voltmeter, soldering tools, LOTS of wire, etc.) .....and patience.

:laugh....so true!...I can't believe the amount of wire I went through! Actually my question was more in line with considering all the holes you drilled, location of wiring and routing...is there anything different you would do there? For example....I do not know about you...but I have never been completely happy with the wires that exit at the bottom of the downtube (and I think we talked about this previously when you were first going through the design phase) just above the rear rubbermount. I think I had more wires running down there then you did and it was pretty tight. I wonder if it would have been better to create a larger hole just above the battery under the seat instead and try to keep ALL of the wires within the battery cover area?

How are your throttle and clutch cables with the drag bars?? Not sure if we talked about this before but I bought a shorter clutch cable (will have to reinvestigate which model it came from if you want more info....but it was about 2 1/2" shorter than the stock nightster but it was a stock sportster item) and I used the stock throttle cables after some rerouting.

For the throttle cable I ran it between the hard front brake line and the front fork tube, around the stem to the clutch side of the bike:
http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/Throttlecable.jpg

I then ran the cables above the front gas tank mounting bolt and under the gas tank:
http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/Throttlecable1.jpg

Then I brought the cables up and over the backbone (all of this is under the gas tank of course) and then down to the throttle body on the throttle side of the bike:
http://i32.photobucket.com/albums/d28/nyjeepman/Nightster%20Gas%20Cap/Throttlecable2.jpg

I zip-tied them to the backbone to keep them in position. If you look at the pic you took in comparison below....I think i was able to get more of my mine hidden and more importantly I didn't have the big loop of cable sticking out front of the bike

http://i784.photobucket.com/albums/yy129/bhibbert/PC220076.jpg

This worked out pretty good for me without having to get shorter throttle cables. Plus I think it hid the throttle cables better. Just wanted to throw that out there.

Hibb5337
15th January 2010, 05:55
i'm going to try to hide the throttle cables a little better like u showed there.. i had to take them off again for test fitting of the nacelle today!! i love that thing. now is the question, do i paint the nacelle brilliant silver or gloss black. cannot make up my mind. i tried changing Pastryslayer's pic in photoshop to see what a silver nacelle would look like, but i suck with photoshop...hahaha. now i'm just trying to figure out speedo options and clamps. hopefully, as more parts keep coming in, i can start tearing away at this thing again.... i hit a lull and got crazy busy with work and a new job with the guard.

Hibb5337
16th January 2010, 02:59
got the nacelle and new shocks this week. test fit the nacelle to get a look for it before i send it off for paint.....black or silver, can't make up my mind.

Cosmo, also.... here are the pics of under the seat and how i moved the ECM. sorry, these are LONG overdue. I also did the zip tie trick through the front cover clip. I didn't mod the battery tray at all. I just zip tied the ECM to the battery strap. I think i'm going to change this later, but it'll do for now.

the nacelle
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8014.jpg

the new shocks. which are too long even with the drop kit. if anybody wants a set, let me know. I'm going to sell these and pick up a set from a street glide.
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8015.jpg

under the seat.... i'm pretty happy with it except I still need to re-route all the wires for the rear turn signals/brakes and the lic plate light so they're not showing. not a big deal
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8003-1.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8004.jpg
the ECM location.... still thinking about revamping this a little.
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8005.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8006.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8007.jpg

the zip tie trick...works great so far!
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8008.jpg
http://i784.photobucket.com/albums/yy129/bhibbert/IMG_8009.jpg

Hibb5337
16th January 2010, 03:03
holy crap...quality of those pics suck... sorry about that. still can't find our camera and had to use my phone.

Cosmo Kramer
16th January 2010, 23:34
Cosmo, also.... here are the pics of under the seat and how i moved the ECM. sorry, these are LONG overdue. I also did the zip tie trick through the front cover clip.

holy crap...quality of those pics suck... sorry about that. still can't find our camera and had to use my phone.

Thanks for the Pics Hibb!....I appreciate it! Don't worry....most people that know my threads expect blurry pics! :laugh Looks great!...well done! I'll add them to my ECM Relo thread later along with a link to your thread.

The zip tie through the front clip hasn't failed me yet after about 7k miles...and it is easy to pull out and reinstall when you need to get the cover open.

.....black or silver, can't make up my mind.

What about something a little different...like the main body of the nacelle the same denim black as the tank and then doing the front trim ring the silver denim and then have a red pinstripe around it to match the tank? Or would that look too much like a woman's breasts?? :doh Fitting for a girl's bike right?? :roflblack

Hibb5337
17th January 2010, 00:35
What about something a little different...like the main body of the nacelle the same denim black as the tank and then doing the front trim ring the silver denim and then have a red pinstripe around it to match the tank? Or would that look too much like a woman's breasts?? :doh Fitting for a girl's bike right?? :roflblack

hmmmmm.......i'm not sold on the flat black for the nacelle. i like the gloss because it matches the forks, shocks, frame, side covers, etc.....

silver would definitely be different, but i still can't really picture it....(anybody good with photoshop????)

I do think the two tone silver and black would be pretty cool

nightsterfreak
19th January 2010, 16:16
I hid all my wires under the tank when I lifted it 2 inches, works out great! I am not an electrician and I would screw up the wiring!!!

Hibb5337
24th January 2010, 02:46
New Speedometer came in today. I got it off an 09 ElectraGlide. Same size and in perfect condition. But I soon realized the one difference that could cause a problem. (maybe)....... the gas light stays on when I plug the one in from the ElectraGlide. Goes off when I plug the old one in. I assumed it was because the one from the EG has a much bigger tank and trips the light at a certain amount, but actually have no clue. My tank is full currently. Hmmmmm....any ideas?

vagabond65
24th January 2010, 04:11
New Speedometer came in today. I got it off an 09 ElectraGlide. Same size and in perfect condition. But I soon realized the one difference that could cause a problem. (maybe)....... the gas light stays on when I plug the one in from the ElectraGlide. Goes off when I plug the old one in. I assumed it was because the one from the EG has a much bigger tank and trips the light at a certain amount, but actually have no clue. My tank is full currently. Hmmmmm....any ideas?

Could it possibly be that the EGlide speedo is programmed/wired for a fuel guage & is not showing any signal at all (since the sporty doesn't have one) & automatically pops up with low fuel indicator? That would be my guess - which have been known to be wildly inaccurate before.

raaaaaa
19th April 2010, 06:40
wow just read the entire thread and that is a big job, you got balls!!! that nacelle looks great in black, and the bike would look great with the motoscope mini hadlebar clamp, there is one up on ebay right now....I know the clap is like $280 but the one on ebay is only $99.....the bike looks great