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Gotse Inspector
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Mon Mar 19, 2012 3:10 pm 
Sorry these pictures don't help much for the do it yourself'ers. But here are some quick pictures.

Top of motor showing wire loom. The clips for the harness are hidden under the right side of the mount.
Image

This picture shows the Zoomania front frame cover, with this piece you will NOT have to tuck wires on the very front of the front frame. Pic also shows the obvious Daytona gauge with some loom on it.
Image

Quick shot of the tail light wiring. I just used some grommets and wire loom. The grommets are the biggest pain in the ass to keep in place though! I'll continue to search for ones that fit better though.
Image

This is the only link of the harness that can be seen on the front frame. I drilled a hole in front of the lower frame to frame bolt. Un-pinned all the connectors and ran it through. Then RE-pinned all the OEM connectors. :mrgreen:
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Mon Apr 02, 2012 12:06 am 
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http://www.hondatuningmagazine.com/feat ... to_08.html

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Shot Caller
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Mon Apr 02, 2012 12:11 am 
yeah! "open my seat to see how much gas i have?"

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Mon Apr 02, 2012 12:16 am 
thekhmer wrote:
yeah! "open my seat to see how much gas i have?"

Same thing I just thought....in a way, it defeats the purpose :meh:

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Gotse Inspector
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Mon Apr 02, 2012 7:48 am 
Maybe its a different S6 gauge? Maybe a volt meter?

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Wed Apr 04, 2012 8:36 am 
Anyone else have any pics of the routing on the front frame? Let's keep this thread going!

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Wed Apr 04, 2012 2:45 pm 
just drill out the spot on the front frame looks like a oval with some casting material around it . if not taking the plugs off make sure you open up the hole just big enough to get them thru

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Habitual Offender
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Wed Apr 04, 2012 8:17 pm 
Hotrod_Hell wrote:
Anyone else have any pics of the routing on the front frame? Let's keep this thread going!


This, not to mention do you need to cut that wiring harness?

Also what about the cable side of the front, any tucks with that?

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Wed Apr 04, 2012 8:43 pm 
Wheres everyone getting there wire looms from. Preferably someone who has wire tucked and bought some chime in.

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Thu Apr 05, 2012 7:07 am 
2legit2quit wrote:
Wheres everyone getting there wire looms from. Preferably someone who has wire tucked and bought some chime in.


cableorganizer.com

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Sun Apr 08, 2012 7:27 pm 
Anyone have pics of tucking wires through a chine bone?? Think thats what I'm gonna do.

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Sun Apr 08, 2012 7:47 pm 
What's everyone using to grab and fish the lines through the frame?

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Gotse Inspector
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Sun Apr 08, 2012 8:20 pm 
Nemesis wrote:
Anyone have pics of tucking wires through a chine bone?? Think thats what I'm gonna do.


Buy and chin bone first and get back too us. Not going to be easy. I have my throttle cable tucked under mine, it would make taking the battery box off, IMPOSSIBLE.


And for fishing the wires through, I use a k20 dipstick or nothing at all most times. A coat hanger could easily do the job too. Or they have actual tools for this at the right hardware store...

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 Post subject: Re: wire tuck tips and tricks
PostPosted: Sun Apr 08, 2012 9:40 pm 
amt ruckus tucked his through the chinbone. if you ever need to detatch the rear box goodluck..even a chinbone itself makes it complicated..but working on the ruckus with a chinbone is alot easier u just slide the box back and it holds up rather than letting it sit on the gas tank( thats what i do )

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The Carburetor Boys
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 Post subject: Re: wire tuck tips and tricks
PostPosted: Sun Apr 08, 2012 10:55 pm 
Here is steps from my harness and cable tuck\\\

I first start by completely wrapping the stock harness of any shrouds and tape..
I actually had to re-route the harness on both sides of the neck..
I plugged everything in to where they needed to go and just started making new legs where I wanted everything to go..
The connector that plugs into the bottom of the ECU is routed on the right side and not up the left side like stock..
I then had two seperate legs that I could run from either side down towards the neck..
This allowed an easier fit when trying to secure the NADGuard..
running just one leg was to thick and the NADGuard would just smash the harness when tightened down..
So running two smaller legs was what I found worked best..plus having the cables running down there as well made things wicked tight..

Image

Image

In the above pic you can see the two legs a little better..I then joined them back toGETher and then split them again 3 inches later..just the harness builder in me I guess..
but what I did here is only route what needed to go to each side..so the right side got the stator and trigger wires as well as the coil wires..I do have plans to re-wire the CDI so all that needs to go back there is 2 wire and not 4 like it is now..
The other thing I would change is the brake all the brake light wires on the right side as well..right now they run up the left side and that wasn't smart of me becuz the the seat opens from that side so the seat cannot be opened all the way without unplugging the brake light..


Peep the gas tank..I epoxyed tabs to it to secure the harness and cables to with zipties..
Tucks everything up nice and outta the way of road debris..

Image

The stock length of the stator wires is super long so I routed them in front of the tank to soak up the extra length and put them in a place where they wouldn't take up as much room..perfect home for them right in front of the gas tank..you can GET a better perspective by the above and below pics as to the wire locations

Image

I'll be completely finished when I can route the cables and harness into the rear frame and have it all hidden..
but that will require the use of custom wires and connectors..
What do I have in store :evil:

Image

Image


Someone say....custom..
this is what I do for a living..
smallest wire in the is a 22ga but have access to 24ga ATM as well..


Image

Image

If you want custom wiring done...shit aint cheap...but we can talk..
What you are seeing there is called a contra twist where several different cores of wire are twisted in opposite directions and gauges to produce a water hose like leg..perfectly round..this allows the harness to bend and maintain the bend while not stressing the wires at any point.
It's almost sexual for me to twist a bunch of wires like this..

I really enjoyed this project on my Ruckus and can't wait to put the final finishing touches on it soon..
Deutsche baby..you guys ain't ready

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Last edited by GETSlim on Sun Apr 15, 2012 1:59 pm, edited 1 time in total.

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