My 2006 919 buildup... - Wrist Twisters
 
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post #1 of 32 Old 01-17-2007, 07:17 PM Thread Starter
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My 2006 919 buildup...

As requested, I've started a thread for my 2006 919. I'm going to outline as much as I can as to what I've done and what I have yet to do.

Here is the bike soon after I got it. At this point, all I had done was integrate the rear turn signals into the brake light, completely remove the rear fender and replace it with a home made bracket, and remove the grab rails and install mesh underneath to replace them.


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post #2 of 32 Old 01-17-2007, 07:18 PM Thread Starter
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Soon after that, I managed to snag an Akrapovic Titanium and Carbon Fiber exhaust from a Hornet owner in the U.K. I had originally planned to get a Sato since that's one of the most popular choices until this deal fell in my lap. In my opinion, it sounds amazing!



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post #3 of 32 Old 01-17-2007, 07:18 PM Thread Starter
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After seeing how a lot of people were happier with slightly more aggressive bars I decided to try an inexpensive set to see what I thought. On my way back from the bike shop I happened to stop in WalMart. That netted me my other mod for that week...dual headlights!


This pic was actually taken more recently after I put on my smaller turn signals.

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post #4 of 32 Old 01-17-2007, 07:19 PM Thread Starter
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While I always like to be different, not every mod can be unique. Ever since I saw TrickHornet's bike, I liked the Cyclops headlight he had. I recently had the opportunity to trade my stock headlight for a near perfect Cyclops and now I've got it installed. Here is a pic from the first night I got it:


Obviously, the white shield didn't go too well, so I had the paint and body shop at work throw a coat of low gloss trim paint on it. MUCH beter, IMO.

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post #5 of 32 Old 01-17-2007, 07:19 PM Thread Starter
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My mounting options were a bit different than 'Hornet's since I got rid of my stock brackets. At best, it would have been extremely tight to keep the stock gauges, so I decided to remove them. In their place, I intend to install a set of Veypor gauges since they do almost everything the stocks do and more. Unfortunately, with the loss of the gauges, I also lost my turn signal indicators, oil, FI and neutral lights and my low fuel light. With a little thought, I was able to create an indicator light panel that seems to integrate pretty well with the bike. Currently, I have all but my fuel light functioning. If anyone has any insight as to what I might be missing, please step forward!


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post #6 of 32 Old 01-17-2007, 07:20 PM Thread Starter
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The only other mod I have that I haven't listed so far is the CRG mirrors. I'm crrently only running one due to a fitment issue since I cut the moto-x bars down. I'll put the other one back on once I get the bar end adapters from CRG.

The Veypor gauge should be here in the next day or so, so I'll be sure to provide pics when I mount it up. Here's what it looks like for those that haven't seen them...


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post #7 of 32 Old 01-17-2007, 07:20 PM Thread Starter
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Now for the overall pics of what I've got so far...




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post #8 of 32 Old 01-17-2007, 07:43 PM
 
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Lookin Good Reese. Good job man.

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post #9 of 32 Old 01-17-2007, 07:58 PM Thread Starter
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Thank you, sir! Me and the guys hope to get back to your side of the world soon!

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post #10 of 32 Old 01-17-2007, 08:18 PM
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would really appreciate an update when you install higher watt bulbs. when i ride to work its still dark outside and i really am concerned about visability.

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post #11 of 32 Old 01-17-2007, 08:29 PM Thread Starter
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Sure thing!

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post #12 of 32 Old 01-17-2007, 08:32 PM
 
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I would have questioned the look with out the stock gauges, but I think you have really pulled that one off brilliantly.

The bike looks sweet!

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post #13 of 32 Old 01-18-2007, 06:28 AM
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919 Low Fuel schematic

reese - This schematic should help. The circuit is pretty simple. I would start out by disconnecting the 3 pin connector, apply a ground to the pin containing the brown/black wire, and see if the LED lights. AT the same time make sure there is 12 volts being applied to the LED


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post #14 of 32 Old 01-18-2007, 10:12 AM Thread Starter
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Mike, that's what we had tried before. It works great while the 3-pin is disconnected and jumpered but as soon as I reconnect it, the light stays on. There's about 3 galons in the tank, so I know it's not that.

I am using that black/brown for power to the neutral switch and the oil switch but I don't think that is causing the issue. I put the bike in gear and started the bike so that neither of those lights were active. Fuel still stayed on.

Any other ideas?

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post #15 of 32 Old 01-18-2007, 10:48 AM
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You got some awsome shots there. Very artsy, magazine worthy I'd say.

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post #16 of 32 Old 01-18-2007, 11:05 AM
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reese, a couple of more ideas. Raise the tank, make sure there are no wires pinched. Just for the he** of it run the black/brown power lead directly to the 12 volts. In other words bypass the the neutral switch and the oil switch. If these all check good it is leaning towards the fuel sensor. I could not find a resistance reading anywhere in the shop manual. My guess is the resistance should be high otherwise the light would be on all the time. Measure it if you have a multimeter. One last question, was this LED functioning properly before you began the modifications?

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post #17 of 32 Old 01-18-2007, 11:07 AM Thread Starter
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Mike, yep, the fuel light worked fine with the stock cluster. No problems there, so I seriously doubt that the fuel sensor suddenly went bad. I'll try the direct wire a little later. I've got to go work on a 240sx for a friend.

Oh, is it possible that in the cluster there is something that works on a ramped input? (i.e. the resistance varies or once it hits a certain point something on the circuit board lets the light come on/go off?). Just spitballing here.

Thanks for the sugestions!

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post #18 of 32 Old 01-18-2007, 11:14 AM
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Ah... a good clue it worked before the mods. Isolate and test the circuit as if it opreates all by its self. Report back

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post #19 of 32 Old 01-18-2007, 02:04 PM
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Looking awesome reese! Keep up the good work.

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post #20 of 32 Old 01-18-2007, 04:02 PM Thread Starter
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Mike, no go. Using the black/brown as 12v and brown/black going to the other side of the LED keeps the light on all the time.


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post #21 of 32 Old 01-18-2007, 04:51 PM
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Quote:
Originally Posted by reese919 View Post
Mike, no go. Using the black/brown as 12v and brown/black going to the other side of the LED keeps the light on all the time.
Freekin' electrical gremlins. If you disconnect the 3 pin connector the light goes out, correct? Then the problem must between the 3 pin connector and the low fuel sensor, agree? Next, disconnect the leads right at the tank and see if the light is ON or OFF?

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post #22 of 32 Old 01-18-2007, 10:25 PM
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Nice custom 919, let me know if you got a good deal on your Veypor gauge, I need one but I cant come up with the $499 for the VR2 and SportVue HUD Package.

post #23 of 32 Old 01-18-2007, 10:36 PM
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Nice custom 9er!

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post #24 of 32 Old 01-19-2007, 12:17 PM
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Awesome looking bike! Nice mods!

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post #25 of 32 Old 01-23-2007, 03:56 PM Thread Starter
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Well, my Veypor showed up last night, so guess what I was up doing into the wee hours? LOL.
I took a few pictures of what I was doing while installing everything. Keep in mind that this is not a comprehensive installation guide; just a bit of insight as to what I did.

First off, I lifted my gas tank up so I had access to where I intended to run my wiring, etc. I ran the main plug for the actual unit right along the frame and up to the bars.


Here you can see how I ran the wiring (grey wire) along the frame beside the factory harness.


What you can't see in that pic is where just in front of the coolant cap I ran the ignition pickup wire over to the left side of the bike to tie into the coil wiring like this:


And, with the coil back in place, you can't even tell:


I continued running the wiring on back to where the speed sensor was to be mounted. I zip tied the harness to the brake line and then mounted it at the furthest point back. The magnet for the sensor had to be within .8" from the pickup, so I drilled into my brake rotor and left just a bit sticking out. So far it seems to be working fine.



The Veypor doesn't have a power button and I didn't want it to be on all the time, so I tapped into the power supply wire for the meters at the fuse block. The ground wire I simply ran to the negative terminal on the battery.



Turn the key on and voila!


I still need to go in and set up all the features such as gear indicator, fuel consumption, tire size, bike weight, etc., but that won't really be an issue. So far, the only thing I'll probably change is how the speed sensor is mounted in the back.


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post #26 of 32 Old 01-23-2007, 06:08 PM
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Now, that is cool!!!

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post #27 of 32 Old 01-23-2007, 06:21 PM Thread Starter
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Oh, a couple more pics of it...




I got the gearing all set up and the newest firmware update for it. Pretty neat stuff! The gear changes have about 1/2 second delay on them but I don't see that as an issue.

Oh, if anyone wants one, I have the code they sent me which will give you $20.00 off any of their stuff. Just drop me a message if you need it.

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post #28 of 32 Old 01-23-2007, 07:09 PM
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Do you have more info/pics with the dual headlight setup? I like that look.

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post #29 of 32 Old 01-23-2007, 07:54 PM Thread Starter
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Acerbis Cyclops. Roughly $125 new from what I've seen. I traded my stocker for this one. There's a pic of TrickHornet's bike with the same lights somewhere around here. Difference is that he's using the stock bracket to mount his.


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post #30 of 32 Old 01-24-2007, 02:55 PM
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Sorry, I meant the WalMart setup! Looking for a pic of your whole bike with those lights.

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post #31 of 32 Old 01-24-2007, 03:50 PM
 
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Reese...I was also wanting some more specifics on the dual headlight set-up from Walmart (size, wiring, etc)...could you please post some info on what you had to purchase and set-up...loved the dual set-up with the larger size lights...Thanks...

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post #32 of 32 Old 01-24-2007, 04:36 PM Thread Starter
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Heh. I'll sell them along with the bracket and 100w bulbs if anyone is interested! Let's see...$45 for the lights, $15 for the two bulbs, $10 for steel and making it... How's about $55 plus shipping? The bracket is a direct bolt-on in place of the stock headlight.

I just looked around in the auto section of WalMart to see what was available. Pretty much everything they had was bottom mount since they're designed to go on a truck light bar or bumper. As far as wiring, it was just a matter of deciding whether I wanted one light on for high and one for low or both on at the same time. Parts needed: spade connectors (male) to plug into the stock harness and some extra wire. Not much, really.

Dirty, here's the pics.



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