I picked up the mini ape bars, new grips, and cables to install on my Nightster and had
a couple questions. I searched and didn't see anything specific to tools needed.

When removing the tank to install the new throttle cables, the service manual says to
remove the fuel tank and asks to use a fuel transfer pump to empty the tank.

Is there a good place I can pick up a pump to do this? Sears, etc?
Also, any recommendations on wires to use to lengthen the wires?
The dealer said I'd have to add about 4" to the wires, on/off, blinkers, ect.

Also, will I need any other tools? I have hex and torx bits, and sockets to do most of the stuff.

I was suprised I need to remove the tank to do this install, but I guess I'll get up close and personal with the scoot
over the next few days.

So far the service manual seems to be a great resource with pics and step by step instructions.

 

Remove tank to get at wiring connector and easier to run throttle/idle cables with tank out of way. For the wiring look up Novello, they make wiring extensions that require no splicing or soldering. As for the fuel transfer pump. Save your money, ride until the tank is almost empty.

 

I was able to re route throttle/idle cables on my 1200 custom without completely removing the tank, just removing the bolt andjacking up the front end. Otherwise, just run the tank till you hit reserve and then go several extra miles to get the fuel lower, then you can take it off with the fuel in it.

 

Removing the tank serves two purposes... one its a lot easier to do the work... two is you don't have to worry about scratching or dinging it....

I didn't worry about dumping the gas... just undid thefuel and vaccum lines... bolts and nuts and lifted her off... its just not that heavy....

I extended the wires with 16ga wire and soldered them together.... the wiring entension wasn't readily available (probably the better way to go)

Some openend/boxend wrenches a long with a cresent would go well with the tools you mentioned...

Have at it and good luck...

Charlie D.

 

Thanks everyone. I talked to the service dept and they said they had the extenders on the wires and tried them,
with another Nightster but said it looked bulky because the connectors are visible. I know how to solder,
so it should be a problem. I'll let you know how everythings goes.
I plan on starting tonight after work, and I work weekends, so it may take me a few days to get it done.

 

If you WANT to pump out the gas,Auto Zone has a really nice one
thats on the cheap and works really well...

its back there with the grease guns.. assuming all AZ's are set up the same