NY-LONG ISLAND service - Page 12 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #276 of 285 (permalink) Old 6-4-2019, 7:26 AM Thread Starter
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Tank removed, no help, proper main harness routing still in question, though I've found correct locations for more relays and their wiring extensions...but more relays and fusebox need a home, i'm just not seeing it. I'll be doing further homework, researching other owners pictures on the net.

To be continued......4 banger carbs on the hit list today

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**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #277 of 285 (permalink) Old 6-11-2019, 9:06 PM Thread Starter
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Bingo, found a proper home for the main harness run, routing all falling into place, as are connections! Sticking out like a sore thumb are some real boners inherited from the "electricians"....3 or 4 wire runs cut short and dangling, additional wires that they tapped to steal power from various points, I'm removing the bush league crap and repairing as I go along....process of elimination wire by wire. Downright ugly, I'm accumulating a large pile of wiring and junk they saw fit to add in hacks...including wirenuts.

I have a theory the forks were removed, wiring hacked while apart, then the front end reassembled afterwards....irresponsibly causing the extreme routing issues involved....the goal a quick trade, sell or unload...certainly not a responsible job in wiring. What a freakin' mess.

Method to his madness, my bud got it for near nuffin', all along knowing where it would end up for proper repairs.

Correctly clearing codes next, then fork seals should have this thing done. He may want new LED turn signals, I forget, no biggie.

Our goal to get wiring repaired, and everything required to pass NY state inspection, fully legal and roadworthy.

We WILL do this.

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**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #278 of 285 (permalink) Old 6-13-2019, 2:25 PM Thread Starter
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Pic of removed excess crap, rookie mess from harness so far, I removed airbox which revealed Pair valve hose disconnected, left hangin'. Found a finger loose hold down bolt on the main ground strap beneath the fuel tank.
Replaced some incorrect top triple hardware.

Seems I'm finding presence of incredibly sloppy work everywhere I go....electrical and mechanical. Thankfully the throttle body adjustment screws are undisturbed/factory sealed and I was able to remove spark plugs without fanfare....likely never touched ...they'd otherwise be frigged up or somehow mangled. The disgusting air filter confirms, wonder of wonders... certain stuff was left undisturbed (of course a new one would have costed money)

What animals were in this thing.....but all will be well again once their leftovers have been wiped clean.

Waiting for some minor parts....its getting there. 2 engine bolts missing, drive chain needs wipe and lube, USD forks get seals and fluid....fairing reattach and some lighting upgrades....that should do it.

Like a resurrection, saving it from the scrap heap for sure. Yup thats me alright
Attached Images
File Type: jpg triumph13.JPG (171.1 KB, 11 views)
File Type: jpg triumph 14.JPG (128.1 KB, 11 views)
File Type: jpg triumph11.JPG (158.0 KB, 12 views)
File Type: jpg triumph15.JPG (130.6 KB, 12 views)
File Type: jpg stooge4.jpg (18.7 KB, 12 views)

Custom Carb Service

**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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Last edited by ducatiman; 6-13-2019 at 9:52 PM.
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post #279 of 285 (permalink) Old 6-17-2019, 8:49 PM Thread Starter
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Consistent progress being made...sidestand switch wiring was cut, totally inop....fully repaired, clean and invisible. Engine cooling fan wiring cut ...now repaired and ditto. Radiator and cooling fan previously loosened to enable re running some misrouted harness runs have been remounted. New spark plugs, air filter and airbox all reassembled. Pair (SAIR in Triumph speak) valve properly reconnected and installed.

Tomorrow finalizing some forward harness runs using corrected routing.

Its beginning to look neat and tidy again in spots I've addressed, other areas still in process. My pile of removed,ugly, unnecessary wiring and associated junk has reached its peak now, I think. I'll pop a pic, good for a laugh.

Once the harness is fully intact, the job of eliminating flipped codes begins....one by one, slow but sure. I think my work today on re-enabling some previously disconnected electrics will eliminate a few codes, actually.

Fork seal replacement and steering stem bearing check/adjustment on the horizon.

Not being a previous owner to the 675 Daytona, nor having any reference (other than a Haynes manual and internet forum resources) while inheriting incredibly sloppy leftovers from prior owners.....all in total a huge undertaking, problems at times slowing me down to a crawl, requiring massive research.

I'm revitalized now finally seeing some positive results! Horrific weather forecast means I'll be "on it" this week. After pics, when justified, will ensue. This gonna be a mean, lean, very fast machine, I think.


Thanks for allowing and enduring all this boring dribble.

Custom Carb Service

**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #280 of 285 (permalink) Old 6-18-2019, 8:15 PM Thread Starter
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Electrical efforts have culminated in decreasing previous 12 codes down to only 1 today! Even that one was predictable as its subject, an exhaust control valve servo has been removed. The bike left side is beginning to visibly tidy up.

Tank, seat, tail section will go back on shortly.

Slowly chipping away, getting there.
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File Type: jpg triumph16.JPG (148.8 KB, 15 views)
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Custom Carb Service

**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #281 of 285 (permalink) Old 6-20-2019, 2:11 PM Thread Starter
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I'll reserve comment on "the pile" (damn if I haven't just nicknamed this Triumph ) but work commences...between dedicated laptop cabled to Triumph using Tune ECU (a very friendly program) learning, doping my way around...I'm permanently getting rid of the EXUP valve code, via deleting the valve from the map.

2019 = tuning by computer
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File Type: jpg triumph17.jpg (179.7 KB, 7 views)
File Type: jpg triumph18.jpg (91.9 KB, 5 views)
File Type: jpg triumph19.jpg (162.3 KB, 6 views)
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Custom Carb Service

**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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Last edited by ducatiman; 6-20-2019 at 2:17 PM.
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post #282 of 285 (permalink) Old 6-20-2019, 2:14 PM Thread Starter
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So back to work on "the Pile" this afternoon....I think finalizing the inherited harness jigsaw puzzle.
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Custom Carb Service

**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #283 of 285 (permalink) Old 6-21-2019, 10:52 AM
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The wiring mess I removed from my project 900SS was equally bad. I only found a pair of wire nuts though. The majority of a spool of wire too. It was wadded up with the hack HID install wiring and ballast in a huge wad of duct tape. And it didn't even work. Wonder of wonders right? Went hand in hand with the added cigarette light socket in the left hand lower fairing, and the "under glow" strips I found taped to the rear frame tubes....all sans any wiring.



That Triumph found a good home.....at least the new owner knew where to take it to make it whole again.........sean


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My garage: 2000.5 Aprilia Mille R, 2000 Ducati 996, 1994 EX500 basket case, 1993 Ducati 900 SS, 2004 Suzuki GSXR600, 1992 GSXR750 oil boiler, 1983 Suzuki XN-85 Turbo
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post #284 of 285 (permalink) Old 6-21-2019, 11:50 AM
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Quote:
Originally Posted by ducatiman View Post
I'll reserve comment on "the pile" (damn if I haven't just nicknamed this Triumph ) but work commences...between dedicated laptop cabled to Triumph using Tune ECU (a very friendly program) learning, doping my way around...I'm permanently getting rid of the EXUP valve code, via deleting the valve from the map.

2019 = tuning by computer
Triumph have been that way since they went FI with the Sagem system. Not sure if it's the same program nowadays, but back on my '02 955i the software was called TuneBoy.

Glad to see you bringing the bike back to life....

2007 Kawasaki Ex-500 Ninja
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996
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post #285 of 285 (permalink) Old 6-21-2019, 12:46 PM Thread Starter
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Quote:
Originally Posted by Davenay67 View Post
Triumph have been that way since they went FI with the Sagem system. Not sure if it's the same program nowadays, but back on my '02 955i the software was called TuneBoy.

Glad to see you bringing the bike back to life....
The Pile is a 2010 675 with a Keihin brand ECU. It is very likely Tuneboy software could be used as well, though with wide popularity and support on Triumph 675 specific forums, we chose Tune ECU. Luckily I was able to use my onhand OBD link cable (specifically for Ducati use, but without requiring the additional Ducati specific adapter cable).

I've got a dedicated laptop wiped clean of all apps, programs, etc....its now got Tune ECU and guzzidiag which somehow scares the hell outta me, doesn't seem as "friendly" as T- ECU. Otherwise the laptop is devoid of other stuff.

tuneECU does not support the magneti-marrelli brand ECU on my SS800....unfortuntely I'm stuck with guzzidiag on that one.

I'll be frank here....as i'm just getting into "service via computer" I'm intimidated, over my head and scared bleepless I'm gonna wipe out something on the Ducati, screwing up using the complex guzzidiag.
TuneECU so much friendlier, IMHO.

Must rewire rear turn sigs on the Pile, we await a Triumph parts order of proper bracketry for final fairing installation, if you could see the crap these kids used to hang the fairings, you'd throw up....much like the wiring pile. In addition a front fork review...oil change minimum, possible fork oil seals. I need to open them and confirm all parts are present ....justified and required knowing the history of prior "attention" the Pile received from these PO kids.

The owner studying for medical Doctorate...he may well become my primary at some point.

I'm estimating completing the Pile in no more than 10-12 days max, juggling carb work and my own stuff. We're both excited anticipating the final outcome. Pics'll follow when justified.

My personal overview of this project....like doing a jigsaw puzzle without having the final picture of what its supposed to look like, many pieces scattered, missing

Custom Carb Service

**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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Last edited by ducatiman; 6-21-2019 at 12:50 PM.
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