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Remove the fairings, seats, pegs, mirrors, headlight, and windshield brace from the TL1000.  Do this in such a way so as to keep all electrical intact and keep the motorcycle in 'running' condition. We will use the mirrors and headlight in the CabinBike, however, any unused parts can be sold on eBay to recover some of the cost of the donor.

 

You can make a home made "A" frame like we did to suspend the TL1000 so the front end can be removed. Even with the front end off, keep the bike otherwise fully intact.

 

 

Remove the front end and install the TL frame onto the CabinBike firewall.  All the while keeping the electrical system intact and the motorcycle in 'running' condition. Temporarily secure all of the front end electrical, dash, relays, plugs, etc near the rear of the cabin.

 

Extend the TL1000 wiring harness to the front of the CabinBike. To do this we simply separate the TL1000 harness at the 2 main plugs and make an extension cable consisting of 27 wires.  We made a chart (seen here) to help us with tracing wires from the TL1000 harness in the front through the CabinBike harness and back to the TL harness in the rear. This chart may be specific to this bike, however, it will give you an idea of the chart needed when making an extension cable (due to the fact that colors of wires in the stock TL1000 harness may not match wires used in the extension cable.) Ultimately, simply make sure the TL1000 wires match up at each end of the extension cable regardless of the colors used to make the extension.

Install the parking brake onto the swing arm. Install the extended rear brake hose, install the extended clutch hose (FIG. "C" below), install the extended throttle cables.  Move all of the vital controls including the stock gauge cluster to the front of the cabin.

 

Figure C.   

We took the old clutch hose to a specialty shop (Alternative Hose, Irwindale, CA) to have a longer hose made. The new hose needs to be 97.5 inches long plus the ends (see FIGURE "C").   The new hose runs from the clutch slave, under the landing gear on the left side, under the chassis, up inside the front wheel well, through the dash, and to the clutch master cylinder on the left side of the handle bars.

 Be sure to leave enough slack to allow full movement of the handle bars. Be certain the hose does not rub or bind.  The hose is secured in several locations along the underside of the chassis. 

 

The TL1000 has 2 throttle cables. One to pull the throttle open and one to pull the throttle closed. We took the old throttle cables to a specialty shop (Flanders Company in Irwindale, CA) to have longer cables and housings made. We re-used the existing ends and fittings from the old cable assemblies.

 

Figure D.  

 The new cable housings are 114 inches long and the cables stick out of the housing the same amount as the stock cables (see FIGURE "D"). The new cables run from the handle bars, under the chassis on the right side, cross to the left side, up into the cabin just in front of the firewall then through the firewall to the engine area on the left side.

 Be sure to leave enough slack to allow full movement of the handle bars. Be certain the cables do not rub or bind.  The cables are secured in several locations along the underside of the chassis. 

 

Install the TL1000 front fork assembly into the CabinBike. Support the cabin at a level high enough so as to allow enough room to fit the forks and front tire under the front end.

 

 

The 'fork pass through disk' seen here goes between the underside of the cabin bike and the fork assembly. This helps seal up the interior from the outside elements. Remove the top triple clamp and slide this over the forks before installing the fork assembly.

          

 


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CabinBike.com and CabinBike™  are trademarks of Fred Nelson Fabrication. 2012-present.

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CabinBike.com and CabinBike™  are trademarks of Fred Nelson Fabrication. 2012-present.

All rights reserved