03 620 Dark - PLEASE help me figure out some starter mods

[ducjon]

Did my best, could use a little cleanup, but it looks 10000x better!

Got rid of the frame stickers too (but kept them in case, doubt i'll ever need them again)

Only thing i wasn't sure of, was the tie that's right next to the engine.. will that wire melt if it gets too close? I took one tie off, but figured I'd keep the other until I'm sure.

Thanks guys!

[Spidey]

Got rid of the frame stickers too (but kept them in case, doubt i'll ever need them again)

Keep the emissions sticker that is under the seat (it's the same one that's on the frame).  If it's not there, put the emissions sticker from the frame there.  You may need it if you ever sell. 

[Privateer]

Did my best, could use a little cleanup, but it looks 10000x better!

Got rid of the frame stickers too (but kept them in case, doubt i'll ever need them again)

Only thing i wasn't sure of, was the tie that's right next to the engine.. will that wire melt if it gets too close? I took one tie off, but figured I'd keep the other until I'm sure.

Thanks guys!

looks good.  Mine's an 04, very similar:

on the left side, i ran everything through a loop on the head that was holding a hose from the airbox.

on the right side, i mostly just cleaned up some of the routing.  there's a set of wires that went under a cross piece in the frame, so i pushed it over that piece.  then a few pieces going back to the rear I just zip tied to other hoses and wires.

here, i took a couple pics while I was typing.

[Goat_Herder]

I've noticed the clutch is really a tough pull, I rode a 695 and 696 and it seems wayyy easier of a pull.. My hands get crazy cramps around the city.. Is there a way to modify this cheaply? I'm thinking maybe aftermarket levers that are adjustable and give me a shorter distance to pull..

I noticed that my 620 has a heavy clutch pull and the contact point is really far.  In traffic, my left hand got tired really quick.  Best solution - Pazzo levers.  I set the clutch side at 2 and brake at 1. 

[Scooter Montgomery]

Nice job on removing the zip ties.

[Scooter Montgomery]

Hey it's nice to finally see some others of our rare color scheme for 2003. An interesting fact is that there were only 199 of our type sent to the US in 2003.  

I guess we know where 3 of them are. 

[ducjon]

Found a small trick, you can get rid of the bottom zip ties, if you use the inside of the frame.




Privateer, I'm guessing this issue is why you left the two lower ties on?

[ducjon]

Anyone enlighten me on what this is, and how I put it under the seat?

I removed both back covers, it looks awesome! On the other side, I managed to get everything up under the seat and zip-tied down. Now I just need a tail chop!

[Privateer]

Found a small trick, you can get rid of the bottom zip ties, if you use the inside of the frame.

Privateer, I'm guessing this issue is why you left the two lower ties on?

I was a little hesitant to leave the clutch line hanging free and didn't put 2 and 2 together and use the cross support.  Honestly I'd forgotten all about it until you pointed it out.

[cduarte]

Anyone enlighten me on what this is, and how I put it under the seat?

I removed both back covers, it looks awesome! On the other side, I managed to get everything up under the seat and zip-tied down. Now I just need a tail chop!

that's a coil

[cshadow2]

I did a bunch of cheap fairly easy mods to my old 620
1. black out the headlight ring i powdercoated mine but some flat black krylon would do the trick just fine. the most difficult part is taking the headlight appart but it will still be fine with one less spring clip (i know this)
2. chop the stock cans (procedure can be found using search) i would pant the sleeves on them with flat black grill paint on hi temp powder coat them. i took off 7 inches they sound great and look much better.
3. ditch that canister shield when i took off my canister  shield i used washers to replace the thickness of the shield i don't know if you have to do this but i was trying to be safe
4. the tail chop is what it is. it took me a few months to feel comfortable making the cut but once i did it i was stoked it looks so much better
i powdercoated the rearsets but its allot of prep work and i think you silver ones look good with the silver frame so i wouldn't do it if i was you
looks great so far though..

[img]a href="http://www.flickr.com/photos/29402637@N03/2746146633/" title="IMG_0326 by csvasatka, on Flickr"><img src="http://farm4.static.flickr.com/3109/2746146633_e00035e917.jpg" width="500" height="375" alt="IMG_0326" /></[img]