2005 to 2011 transformation questions

[jcborden]

Hi all, been lurking for a while and have a 2005 EC 300 which I purchased the transformation kit for to take it to 2011.

Have read the other transformation threads which has provided some very useful information, particularly on the air box side of things which having read the other threads was actually pretty straight forwards.

So, here is a picture showing where I am up to:

And on to my questions, some of which I am sure are silly, but hey might as well ask:

1. My CDI sat under the tank in a recess in the old airbox - I assume you just move it into the new airbox, but where does it sit and how did you secure it?

2. The mud flap that protects the shock absorber attached to the old airbox by two 6mm bolts (with recessed nuts on the airbox), looking at the new airbox there are just two holes drilled in the plastic - do you just use self tapping screws to secure it?

3. My side stand hits the undertray which can't be normal - any suggestions on how to resolve?

4. The airbox just presses together and is held in place by the subframe - do you seal the joints with anything or just rely on the press fit to keep the worst of the mud/water out?

5. The rear LED brake light has a short lead and connector fitted - is it a special/gas gas connector or a standard one that a car shop would sell? Or do you just chop it off and solder to the existing wiring?

I am sure there will be more, but having got the airbox/boot sorted I feel like I am making good progress.

Cheers.

 

[nknudsen]

We're at different stages of our kit installs but this is what I've found so far.
Make sure the subframe/tail is centered over the rear wheel. The hole location was off on mine at the right top strut that mounts by the tank. If forced into position it made the subframe crooked

Obstacles so far with my 2000 EC250 (not done yet)

*Hole location off on one subframe strut (top right)
*2000 or 2011 FMF TC2 silencer won't fit correct
*Shrouds needed sanding/fitting on the inside to mount to the tank decent
*seat fits very very snug to back bone of the fuel tank

Could your side stand just be bent/tweaked out a bit to clear?

Good luck with the project!
Noah

 

[jcborden]

Hi Noah,

I've got the FMF TurbineCore 2 for a 2007 and the mounts will line up but I can't get it to slip over the end of the header, strange as the FMF I've taken off fitted over just fine. Not sure what to do with this...

There seems to be a lack of fixing points to attach the under tray to the subframe. Need to take another look to see if I've missed anything.

 

[djroggen]

The diameter of the pipe from older bikes is larger than the diameter of the newer I believe 07 and newer run. Forgot about that fact.

 

[Neil E.]

On the 2011, there are two screws that go into the frame from the outside. They attach the plastic CDI holder to the frame.

 

[Neil E.]

View from the inside of the "airbox". The bottom of that CDI holder is screwed down to the airbox. A rubber strap anchors the CDI unit to the holder.

 

[nknudsen]

View from the inside of the "airbox". The bottom of that CDI holder is screwed down to the airbox. A rubber strap anchors the CDI unit to the holder.

Thanks for sharing the pictures!

 

[Tigger52]

When I did mine the shock mudflap bolts were of the self tapping variety so I just re used them and they gripped just fine.

My side stand had a bolt fitted by the previous owner that limits the movement just enough - I think this was because he fitted 2004 plastics on the 2002 bike and the stand was touching the side panel.

I zip tied my CDI unit to the subframe rail, but I'm going to mount it properly now I've seen those pics - thanks

 

[jcborden]

The pictures are very helpful, alas I don't have the plastic bracket for the CDI so will make something up.

I spend quite a lot of time this morning trying to fit the rear plastics only to find that nothing lined up, after a bit of head scratching I realised the airbox was just too far forwards and with a bit of tugging and swearing it is now nearly lined up but should all fit OK.

I will have to see if I can restrict the stand movement or straighten it a bit to stop the hitting.

My biggest issue now is the silencer. I have put the FMF for my 2005 next to the FMF for the 2007 and the outer pipe diameter looks to be the same but there must be a slight difference on the internal diameter. I will try a bit of brute force along with some gentle grinding to see if I can persuade it.

 

[Neil E.]

I will have to see if I can restrict the stand movement or straighten it a bit to stop the hitting.

There was a small hole in the top side of my sidestand receiver. I found a small rubber bumper in my junk drawer and the mounting stub fit through the hole. The head of the bumper was just right to to keep the stand from clunking when it swings up (I changed it to no auto retract).

 

[jcborden]

Well it is finished, just about. Still need to sort the stand so will look at getting it straightened as it probably is a bit bent.

Also had problems getting the front brake line to clear everything as it runs inside the light cowling. Still touches the clutch line but only just so hoping it will be ok.

Managed to get the silencer to fit after a couple of frustrating hours with a dremel. Don't know why it didn't fit, but it's on there now.

Here she is - the airbox panel graphics aren't on yet as I got sent the wrong ones so am now waiting for the correct ones.

I have to say that I was a bit disappointed with the general fit which was off in a few places and required a bit of trimming/filing to get it to go together. However, I am rather pleased with the end result!

 

[nknudsen]

That looks sharp! Can't wait till mine is complete Good job!

 

[Tigger52]

I'm still experimenting with the brake line routing on mine as it did catch when I first converted it.

Seem to be better now I've swapped the brake line and speedo cables.

The bike looks great, well worth the work

 

[nknudsen]

CDI mounting

The pictures are very helpful, alas I don't have the plastic bracket for the CDI so will make something up.

I spend quite a lot of time this morning trying to fit the rear plastics only to find that nothing lined up, after a bit of head scratching I realised the airbox was just too far forwards and with a bit of tugging and swearing it is now nearly lined up but should all fit OK.

I will have to see if I can restrict the stand movement or straighten it a bit to stop the hitting.

My biggest issue now is the silencer. I have put the FMF for my 2005 next to the FMF for the 2007 and the outer pipe diameter looks to be the same but there must be a slight difference on the internal diameter. I will try a bit of brute force along with some gentle grinding to see if I can persuade it.

Where did you end up running the CDI wires and mounting the CDI box? Did you have to lengthen the wires?

 

[steliost]

My '05

Hallo fellow gassers, I just finished the same transformation to my '05. I have to say that the fit of the plastics was near perfect! I didn't face any serious problems along the way, just a few minor ones. I had to drill some extra holes and replace some parts that went missing but I expected more trouble... nice!
Also I tore the bike to pieces and powder-coated frame, swingarm and rims with new spokes.
And here she is...

 

[Rick]

Nice job! Looks Great!

 

[Mattnzl]

Wow! The black frame & swingarm really make that bike look much newer.
How did you get the "carbon fibre" look to the rims/swingarm?

 

[Coop]

Wow great job guys. Your bikes look great!

 

[steliost]

Matt, the carbon look is actually a sticker that is sold by the square meter and it comes in many colours. I thought it would protect the paint job on the rims and swingarm. At least for the first few rides...

 

[Mattnzl]

I figured it was a sticker, but you made such a neat job of it! I can confidently say if I was to put a sticker on my wheels it would look like total crap