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headlight bucket rats nest

Discussion in 'XJ Technical Chat' started by Ltdave, May 5, 2009.

  1. Ltdave

    Ltdave Member

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    WHY do they have to jam every last connector into this mess? of course they have to run the cables in one hole and then out another so you cant just take the bucket off without disconnecting everything...

    [​IMG]

    what fun...NOT
     
  2. RickCoMatic

    RickCoMatic Well-Known Member

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    The Headlight Bucket "Rats Nest" of connections is a bone of contention with everybody who needs to do work in there.

    The Speed Connections are only there to save time BUILDING the Bike.

    There's no reason you can't Clean-up the mess with two hours of soldering and Heat Shrinking.
    (Nearly every guy I have talked too that has done it SWEARS the Bike runs better)

    But, the convenience of just unplugging something will be lost.
    So what?
    How often are you in there ... anyway?
     
  3. Polock

    Polock Well-Known Member

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    did you think they forgot about Hiroshima and Nagasaki ?
     
  4. Ltdave

    Ltdave Member

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    if one were to pass both ends of the connection through the SAME HOLE instead of two different holes, the light bucket could still be removed if necessary...

    i hadnt thought about making hard connections before. i may take that under consideration...

    thanks
     
  5. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    A great deal of order can be obtained simply by sorting them out and rerouting in a logical fashion.

    Is that your 750? Are you going to a round light?
     
  6. Ltdave

    Ltdave Member

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    yeah its the 750...

    i had to replace the plastic bucket that was broken in the accident...

    id LIKE to keep it all original because ive got everything but a lightbulb. the lowbeam (i think) is burned out...

    ive got the fishfinder off the bike too. it wasnt running when i rode it home from the accident but i didnt know if there was a loose connection or something simple. i did notice some wires that were cut thru their insulation but they look like lightbulb leads...

    ive got a set of round meters from an XS but they need some sort of O-ring between the can and the trim ring or theyll fill with water in the first heavy dew...

    that and i dont know how to hook a mechanical tach to an electronic tach output...

    i dont like the acewells enough to spend the money...
     
  7. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    Anybody have any pictures of a "cleaned Up Rats Nest"?????????
     
  8. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Is this clean enough?

    I did it without eliminating any connectors, just "training" and routing; needed to make it more "efficient" so the deeper H4 headlight would fit.

    Ignore the red circles, they just indicate which connectors go to the instrument cluster.

    [​IMG]
     
  9. iadubber

    iadubber Member

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    Wow, that looks nice. This is my next project.
     
  10. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    pre-emptive answer to next question:

    I used rust converter inside the shell; after it dried it was sanded lightly and sprayed with Duplicolor low-gloss black engine enamel, my favorite Yamaha low-gloss black substitute.
     
  11. jgb1503

    jgb1503 Member

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    any tips on how you 'trained' our routed the mess?
     
  12. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    Fitz, I have to ask this. How do you get your stuff so clean. You got a giant dish washer or something you put your bike in or what???
     

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