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Old 03-16-2012, 07:57 PM   #4
Geek OP
oot & aboot
 
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Joined: Jun 2003
Location: 8000ft, Twin Spruce Gap, Colorado
Oddometer: 29,808
So this weekend I have to get it street legal.

Dis assembly photos (lots of details for those curious about how the new 500s are put together):

The seat is removed with a single bolt from below (in the rear fender well) revealing:


The stock cockpit


Dis assembly begins:


Stock... under the headlight is a mess (in fact a bunch of the wiring on the bike is a bit of a disaster.. I am guessing it is because the use the same primary loom as the EXC so there are lots of wires unneeded)






To remove the tank: one bolt in the center of the tank (on the bike's backbone), two screws on the shrowds (one on the outside of each radiator) then quick-disconnect the fuel pump and the wiring plug





Left side:








Right side:






The stock wiring to the thermostat:


The stock wiring in the nose (all the grounds coming together)


Another example of fun wiring.. I'm assuming because the EXC had more stuff connected here..
Nothing like taking the ground wire and giving it 3 potential failure points in a 4 point connector.


Lots of wiring improvements to be made for sure.


...to be continued.

Geek screwed with this post 03-16-2012 at 08:10 PM
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