internal wiring
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Novice
Joined: Mar 2008
Posts: 16
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internal wiring
hey guys, replacing handlebars (and risers for that matter) on my 06 fxdi. i'm really wanting to do internal wiring and i've searched on the do it yourself board and i've seen a lot of guys saying you need to take your tank off and other stuff (most of these guys are softail owners) wondering if this is true and what all internal wiring entails for us dyna guys. any help is appreciated.
Cruiser
Joined: Sep 2007
Posts: 135
Likes: 0
From: connecticut
RE: internal wiring
try this it was good readingMY APE INSTALL
[IMG]local://upfiles/43945/F6E82A1B803D4485B361605E87C71FBE.jpg[/IMG]
[IMG]local://upfiles/43945/F6E82A1B803D4485B361605E87C71FBE.jpg[/IMG]
RE: internal wiring
really good step by step. i did mine with out removing the tank andone otherthing I'd add concerns getting the wire harness out of the frame. it's in there pretty tight and after you cut the zip ties under the seat the slack doesn't want to feed into the frame. there is a square plug in the fender directly in front of the rear tire. pull all the slack through the hole and it will line up with the frame and make feeding the harness out of frame much easier. i did it with the tire on but if i had to do it again I'd probably remove it.
Road Master
Joined: May 2006
Posts: 874
Likes: 0
From:
RE: internal wiring
I swapped out my chrome bars for black bars of the same size , installed poly bushings, internal wiring, drilled out the bars, relocated the directionals, and put on the chrome control button covers. It took me 12 hours broken up into 2 6 hour days.
I did my bars this past winter. I found it to be much easier to access the wiring harness after removing the tank. Remeber to siphon out all the gas. After you get the tank off pull the rubber bushings out from the frame on both sides where the wiring enters the front of the frame.
Then reach under the frame and remove the lower wiring harness cover, reach up inside and pull down the wiring harness. One side is up towards the front of the frame and the other is set back a bit. You will be looking for the 2 deutsch connectors for the controls and the 2 three pin connectors for the directionals. You will have to take them apart. The deutsch connectors are easy. I found the 3 pin connectors to be a bit more difficult. I used a long heavy gauge sewing needle to release the wire tab. The shop manual explains the process for both types of connectors and has the wiring color codes. I've been an elctrician for 18 years and would not have attempted to do it without the shop manual.
It is a wealth of information and has step by step instructions including torque settings for critical fasteners and pictures.
I did my bars this past winter. I found it to be much easier to access the wiring harness after removing the tank. Remeber to siphon out all the gas. After you get the tank off pull the rubber bushings out from the frame on both sides where the wiring enters the front of the frame.
Then reach under the frame and remove the lower wiring harness cover, reach up inside and pull down the wiring harness. One side is up towards the front of the frame and the other is set back a bit. You will be looking for the 2 deutsch connectors for the controls and the 2 three pin connectors for the directionals. You will have to take them apart. The deutsch connectors are easy. I found the 3 pin connectors to be a bit more difficult. I used a long heavy gauge sewing needle to release the wire tab. The shop manual explains the process for both types of connectors and has the wiring color codes. I've been an elctrician for 18 years and would not have attempted to do it without the shop manual.
It is a wealth of information and has step by step instructions including torque settings for critical fasteners and pictures.
Road Master
Joined: Oct 2007
Posts: 1,213
Likes: 1
From: Hot Springs Village AR
RE: internal wiring
I took the tank off and pulled the plugs by the neck the harness came out pretty easy getting in back in was a bitch. I pulled the seat off and pulled away as many wires as I could without disconnecting any and removed the battery and reached down and pulled the wire harness at the same time pushing at the neck and finally went back in I used a set of long curved needle nose pliers to grab the harness under the seat. It woked for me definetly a six packer get good beer to at least you will enjoy that part of it.
Tourer
Joined: Apr 2008
Posts: 279
Likes: 9
From: Houston, Texas, USA
RE: internal wiring
I did it without removing the tank. Just remove the front and rear tank mounting bolts and pull the tank toward the seat. Remove the plastic cover under the frame where the wires go in near the neck. It has two tabs that you have to squeeze together to get it to come out. Use lots and lots and lots of towels, rags, and blankets to protect the tank while you're doing this. One slip of the wrench and you fu*ked up your paint. Believe me, I know. Oh, and also use lots of towels and rags to protect the tank.
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RE: internal wiring
i drilled, then cutthe lines, from there i added in ext and then soldered it all back together... easy as pie... to pull the wires i blew fishing line through the holes till it came out... then just pull the wire though... simple job... if you need help let us know... oooh ya! be sure if you are drilling out that you really take your time and getting the edges down.. if not it will ground out your bike... it was put to me like this, "you should be able to pull a cotton ball through and not have it snag" i do mine a bit diff cause i set my bars up for plug and play, this way i can just unplug my bars take them off and put on drags and plug them in... boom new bars... only catch to that is you have to have anoter set of conrols.. that is what gets you
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[IMG]local://upfiles/26534/97C3C0DDF8C644239F46980E8B794141.jpg[/IMG]
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