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Wiring relocation to the coffin

6.8K views 25 replies 17 participants last post by  rcoligan2  
#1 ·
So when I completed the dual-projector headlight project, I was left with the bundle of wires on the left side:

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I talked about tucking the wires in the coffin. I had installed the ChurchKey V-Bak, so I sat down, had a beer, and cut the first wire.

First step was to re-route the wiring loom from the ECU into the coffin. I simply made a U-turn near the coils and fed the wiring harnesses one by one down to the coffin through the snorkel. I took a knife and cut out the rubber wall inside the snorkel to make routing the wires easier.

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Then I took the wires from the controls and the speedometer and fed them in, around, and behind the speedometer. In the end, I decided to not drill any holes in the frame. the left side neck was going to be used for the Tachometer wires, the key barrel wires, and the turn signals so I thought the best place would be to route them right along the top.

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Then began the long and tenuous process of extending the wires. I did it one wiring harness at a time as to not get confused. I would cut the wiring, add a length of wire in the middle, and route it down to the snorkel:

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Connect them all together,

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and shoved them into the coffin along with the DDM ballast and ignitor. It all fit perfectly. :0) Put the gas tank back on, fired it up, rode it up and down my street, and all is good.

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From my perspective, the wires that run along the center are really not that visible. The movement from left to right are unobstructed and fluid. Overall, I'm happy with the turnout.

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#2 ·
Great!

Love the Pics, and like the custom "one of" dual projectors. Can you take a pic at night to show the light pattern from riding position perspective and another from in front of a wall to see the cut-off pattern?
 
#5 ·
Love the Pics, and like the custom "one of" dual projectors. Can you take a pic at night to show the light pattern from riding position perspective and another from in front of a wall to see the cut-off pattern?
Search for his original thread on this, he did all of that :)


Yunebug, that's a buttload of wiring! It would take me about 12 hours, because I'd do one wire at a time to make sure I didn't screw it up. Man, what a lot of work!

Great job. :D
 
#13 ·
lol - Having a high school teacher leveled patience definitely got me throughout it, I think. :0)

All of this for a headlight? I guess so. Cleaning up the wiring is part of the aesthetic appeal of the headlight swap, I think. Also, this will allow me to easily change my headlight options in the future for an updated look when I get bored with this set up.
 
#15 ·
Yeah, LD - that yellowing was there when I bought the bike. The stock setting was at -5 for the front cylinder - apparently too lean. Since the Churchkey VBAK install, I bumped it up to +2 as per Woody's instruction. I'm going to check the plugs at my next oil change, which is coming up in about 100 miles.

Good eyes. ;0)
 
#24 ·
Do we have a California Warrior on the forum anywhere? Seems like most states are represented here. :0)

Most definite improvement over stock. I really could not see a lot of the road before. I've had HID installed in all of my cars and motorcycles I've owned in the past, so anything less is seemingly dim. There's a (poor) shot of the light output on page 1. If someone has a light output of a stock headlight, it'd be a good comparison.

Working on that photo for you, G.