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 Post subject: Speedo in the Battery Box (pj version)
PostPosted: Tue Oct 02, 2007 5:56 pm 
Edit: When taking your speedometer off, follow the wires into the battery box and disconnect them from the wire harness by unplugging them. Do not try to pull the lights out of the speedometer. You may have to take off the front cover to do this.

Part 1:
So heres how I went about moving the speedo to the battery box. First using a caliper I measured the diameter of the speedometer to be 2.56 inches. Then using a compass I made a 2.56 inch circle on a piece of cardboard to use as my template for the hole to be made in the battery box. I then used a sharp knife to carefully mark the outline of the template onto the battery box.

Image

Next I used a dremel tool with a drill bit to make a series of holes on the inside of the outline.

Image

Then using the dremel with a sanding disc I cut between all the holes.

Image

To smooth out the hole I used the dremel with the drum sanding attachment and my knife to clean up the edges. This is also where you make any small adjustments to the hole to make sure the speedo fits.

Image

And here you have it, speedometer in the battery box.

Image

Image

To hold it in there all you need to use is a hose clamp.

Image

Part 2:
Spacing out the ECU.
You may wonder, why would I need to space out the ECU, this is why. Its kinda in the way.

Image

The following hardware is needed to move out the ECU:
(2) 5mm x 50mm bolts
(1) 6mm x 35mm bolt
(2) 36mm (or about 1.4 inch) spacers
(1) 19mm (or 0.75 inch) spacer
and misc. washers

Image

The blue arrows in this picture point to the two 5mm bolts with the 36mm spacers and the red arrow points to the 6mm bolt with 19mm spacer.

Image

Here you can see the ECU moved out.

Image

And with the battery box back on you can see the ECU is now out of the way.

Image

Putting the battery box back on with the speedo in is not an easy task, it a pretty tight fit.

Image

And there you have it, thats how you put the speedometer in the battery box.

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Last edited by PuddleJumper on Mon Sep 22, 2008 3:17 pm, edited 2 times in total.

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One of Us
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 Post subject:
PostPosted: Tue Oct 02, 2007 6:23 pm 
wow great idea to move out the ecu. i did the old "stick it in there" way... i like yours better :) Awesome!!

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Junior Mint
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PostPosted: Tue Oct 02, 2007 7:45 pm 
Looks great, the only difference with mine is I used nylon spacers, I angled mine flat at the top as well, just my personal preference though. None the less nice work


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Needs Training Wheels
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 Post subject:
PostPosted: Tue Oct 02, 2007 7:47 pm 
Very nice write-up and method. This is one of the many cosmetic mods I'll be doing over the winter...so thanks.


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Needs Training Wheels
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PostPosted: Thu Oct 04, 2007 3:28 am 
thanks for the write up...i might have to try this one


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Junior Mint
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PostPosted: Thu Oct 04, 2007 10:25 pm 
Yeah your way seems so much easier and less wire work. thanks


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Needs Training Wheels
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 Post subject:
PostPosted: Fri Oct 05, 2007 7:47 am 
Sweetness, thanks man. I wonder if theres enough clearance for a tach as well, or perhaps the other side. ill have to check it out.


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 Post subject: Re: Speedo in the Battery Box (pj version)
PostPosted: Sun Oct 21, 2007 1:27 am 
[quote="PuddleJumper"]Part 1:
So heres how I went about moving the speedo to the battery box. First using a caliper I measured the diameter of the speedometer to be 2.56 inches. Then using a compass I made a 2.56 inch circle on a piece of cardboard to use as my template for the hole to be made in the battery box. I then used a sharp knife to carefully mark the outline of the template onto the battery box.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb1.jpg[/img]

Next I used a dremel tool with a drill bit to make a series of holes on the inside of the outline.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb2.jpg[/img]

Then using the dremel with a sanding disc I cut between all the holes.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb3.jpg[/img]

To smooth out the hole I used the dremel with the drum sanding attachment and my knife to clean up the edges. This is also where you make any small adjustments to the hole to make sure the speedo fits.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb4.jpg[/img]

And here you have it, speedometer in the battery box.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb5.jpg[/img]

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb6.jpg[/img]

To hold it in there all you need to use is a hose clamp.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/SIBB7.jpg[/img]

Part 2:
Spacing out the ECU.
You may wonder, why would I need to space out the ECU, this is why. Its kinda in the way.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb8.jpg[/img]

The following hardware is needed to move out the ECU:
(2) 5mm x 50mm bolts
(1) 6mm x 35mm bolt
(2) 36mm (or about 1.4 inch) spacers
(1) 19mm (or 0.75 inch) spacer
and misc. washers

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb9.jpg[/img]

The blue arrows in this picture point to the two 5mm bolts with the 36mm spacers and the red arrow points to the 6mm bolt with 19mm spacer.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb10.jpg[/img]

Here you can see the ECU moved out.
Great How to do it! Pictures tells the story. Thanks
[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb10-5.jpg[/img]

And with the battery box back on you can see the ECU is now out of the way.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb11.jpg[/img]

Putting the battery box back on with the speedo in is not an easy task, it a pretty tight fit.

[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb12.jpg[/img]

And there you have it, thats how you put the speedometer in the battery box.[/quote] :)


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 Post subject:
PostPosted: Sun Oct 21, 2007 1:45 am 
^ WTF was that? :D


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 Post subject:
PostPosted: Sun Oct 21, 2007 4:11 am 
varroa wrote:
^ WTF was that? :D


He added a :) at the end. Took him 5 months to post a :) ?

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 Post subject: Re: Speedo in the Battery Box (pj version)
PostPosted: Sun Oct 21, 2007 6:47 am 
camo1 wrote:
:)


Image

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PostPosted: Sun Oct 21, 2007 4:50 pm 
ThunderstRuck wrote:
varroa wrote:
^ WTF was that? :D


He added a :) at the end. Took him 5 months to post a :) ?


he also added:

Here you can see the ECU moved out.
Great How to do it! Pictures tells the story. Thanks
[img]http://i73.photobucket.com/albums/i211/RuckRider/Ruckus%20Mods/sibb10-5.jpg[/img


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Habitual Offender
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 Post subject:
PostPosted: Sun Oct 21, 2007 9:52 pm 
I just did this this afternoon. The ECU is just kind of hanging out in there (I spaced it out with one long bolt I had handy) but it's not going anywhere. I need to get a hose clamp to secute the speedo properly. It is a tight fit, but things worked out OK. I really am glad I decided to do this because with my handlebars (Pro Taper offroad bars) the speedo cable would bind up the steering when I turned to the right. No more binding and a lot cleaner looking now.

I laid down some masking tape on the battery box, traced a circle around the hole saw I was going to use (2.5"), cut the hole, and used a rounded file to enlarge it very slightly to 2.55". The speedo is a snug friction fit so I'm not worried about it moving until I can get a hose clamp on it.

I do wish the speedo cable were shorter! It looks dorky hanging so far off of the front.


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Dirty Sanchez
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PostPosted: Sun Oct 21, 2007 10:35 pm 
You can get shorter cables through Southtek in the classifieds section.

He would order from Tokyo Parts and ship to your door!

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Habitual Offender
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 Post subject:
PostPosted: Thu Oct 25, 2007 7:15 pm 
Here's how mine turned out. Works great. Would love a shorter cable.

Image


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