BD Harness

Energy One
I recently purchased the BD wire harness to eliminate the EHC in my "06"
K-9. I opened the package and am a little overwhelmed...actually alot! As one who has little to no experience in wiring these things, am I in trouble? Should I be hauling it to a mechanic or is it something I can fumble through? I live in Iowa and there is no one in the area who works on BDM. Are the "06" K-9's more difficult then the others? Any insight would be appreciated.
 

stlmikie

I wish I had more money.
You will be fine. There is a how to for it. Read the directions a few times. Watch the how to a few times. Maybe read it once with the thing in your hand then watch the how to with it in your hand so you can just be basically familiar with it. Then go out and look the bike over with directions in hand and give it a go. Any help you may need you will get within an hour or so via the forum.
 

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
I recently purchased the BD wire harness to eliminate the EHC in my "06"
K-9. I opened the package and am a little overwhelmed...actually alot! As one who has little to no experience in wiring these things, am I in trouble? Should I be hauling it to a mechanic or is it something I can fumble through? I live in Iowa and there is no one in the area who works on BDM. Are the "06" K-9's more difficult then the others? Any insight would be appreciated.
You may not be seeing all the sections of the site. Go to the General Section and see the "Opting In" link.

Moved to "Help Wanted" section
 

Fibersnake

Banjo Playing PsychoBilly
If you are tallking about the Harness with PDM, The baisc How To you have already been directed too. Also may want to look at some of Raywodd pcitures from when he did his too. Should be able to find under a search.

The basic are that you remove your old one by disconnecting the JST and various connectors. Pull it out (recommend carefull and do not cut anything, that way you can save the harness if you need to go back or possible help someone else out later).

Depedning on how you model is, you may need to remove the battery box and clean it up to mount the PDM and HCI (Hand Control Module). You will also need to remove the old EHC.

On the old EHC there is two harness (one for power and then the main back bone). ON the new PDM there is one harness for all.

Basically route the new harness up the backbone (take you time and do not get frustrated, can be a pain getting it through-Ray used some dentle pciks to feed the connectors one at a time through the hold in the back bone-some have used a electrical fish tape or something similar like an old speedometer cable or maybe a clutch cable).

Once the harnes is routed properly, route the wires (once again take your time and get them well managed), hook up the new harness to the exisiting connectors of the old componets (use some dielectric grease between them to help waterproof better; condier sliding a piece of shrink wrap over the connectors and once everything is hooked up and tested, then consider going back and shrink wrapping the connectors to give even more water proofing).

Hook all the componets up, lay out neat (biggest problem seems to be in getting them tiddy up in the part that goes behind the electrical covers-so take your time-check the cover to make sure they do not bind, before locking everything in place).

Get everything hooked up, test and then finish it up and go riding.

It is pretty much a plug and play and some of us had modded some of the wires to make a common ground and lessen the connectors to the battery. Something you may want to consider and thus keep the connectors to the battery to minimal and increase protection against loose wires later on at battery post.

Anyone can do it, just take you time, do not get frustrated and route your wires as cleanly as you can and insure there is no binds or conflicts with compontes or the side covers.

Also mine and I think others had two sets of connections for the speedometer, one for the old style and one for the newer Medallion style BDM speedometere. If you have a Dakota Digitial it goes to the old style which is three wire verse 4 for the new Medalion style.

The instruction that came with mine were very good and the schematic was excellent and helped a great deal. Hopefully you have the same thing.

If you get in a bind or have issue, take a break, send a post and myself or one of the many members will help you out as soon as we can get back to you.

Good luck and if you gain some tips to help other out, by all means post them.
 
Thanks to all. I hope to have time to get started this weekend. Considering the snow will be flying here soon I have months to stumble through this process. FIbersnake, thanks for the heads-up on the Dakota spedo, I just purchased one so that info will be helpful as well. If any of you are in Eastern Iowa stop by. I always have cold beer in the shop frig and I would be happy to put you to work.
 
I just had one installed on my 06 K9. First off let me say I didn't install it. Install was Christmas gift from wife. The installer told me it wasn't hard to do, just time consuming. Heres a pic of the finished product



 
"Time consuming" Did he indicate how long it took him? To be honest, if I had someone in the area I could trust I think I would do the same. Thanks for the pic's.
 
Working on my harness and have a couple of questions. This thread #10 I see the main harness depicted as well as a second wire exiting the back bone. What is the second condutor? The bike is the same as mine "06" K-9. Secondly, they talk about a frame ground. Same pic, is that what I am seeing created above the PDM? Lastly, they refer to a circuit breaker. I do not have one. I do have a forty amp fuse. Sould I be checking around for a breaker? Okay....one more. I have two relays in the new harness, there is one listed in the instruction which is the horn relay. The second is the stop start relay not listed in the mounting instructions and but not sure where to mount it? Any assistance would be appreciated.
 
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Fibersnake

Banjo Playing PsychoBilly
Working on my harness and have a couple of questions. This thread #10 I see the main harness depicted as well as a second wire exiting the back bone. What is the second condutor? The bike is the same as mine "06" K-9. Secondly, they talk about a frame ground. Same pic, is that what I am seeing created above the PDM? Lastly, they refer to a circuit breaker. I do not have one. I do have a forty amp fuse. Sould I be checking around for a breaker? Okay....one more. I have two relays in the new harness, there is one listed in the instruction which is the horn relay. The second is the stop start relay not listed in the mounting instructions and but not sure where to mount it? Any assistance would be appreciated.
Not sure, but if you can get a picture I would be more so. Anyway if it is a small wire bundle that you see coming out of picture #10 next to the new harness, if not mistaken that would be coming from you ignition to you coils and starter switch. Trace it down and see if it hooks up the ignition module with a JST connect, the other part of the igntion will plug in to connectors on the PDM.

Still if you get a picture with your finger pointing or something identifying it, would help, but if I have my mind around it right, should be the small wire bundle going back up the back bone and down to the coils/starter key switch.

The 40 amp replace the original circuit breakers, just double check and make sure that no one left the circuit breaker on there also along with the 40 amp switch.

The second relay if it is not able to be mounted with the horn relay, can be mounted anywhere out of the way and where it will not be in stress or create conflict. I think some of the newest harness actual had the horn and the starter relay on dual mount. Can also be tie wrap up to the bundle or somewhere, just make sure it is out of the way of covers and other and not stressed out.


Hope this helps
 
Moesterman....How is the PDM kit install going? Did you get all the answers you were looking for. Let me know if I can help.
 
PDM Harness

I have the harness pulled through the backbone and started wiring. Firstly, the wire/pin location for the tach are not correct on the master harness--eight pin connector and two green wires in lieu of green/yellow as indicated in diagram and matched wire to tach. Secndly I have two wire packages coming from the ignition switch/coil cover. A two lead orange/black for I believe the switch which I have connected to the master harness. There is a second three conductor red/yellow/blue that I believe is from the ignition coils that there is no connector from the master harness. Should I assume it does not connect to the master harness any longer? This is a pain in the A#@!!!!! This is not my thing but I have all winter unless of course you want ot swing by and get errrr- done for me. As always any insight would be appreciated. Al
 

Fibersnake

Banjo Playing PsychoBilly
I have the harness pulled through the backbone and started wiring. Firstly, the wire/pin location for the tach are not correct on the master harness--eight pin connector and two green wires in lieu of green/yellow as indicated in diagram and matched wire to tach. Secndly I have two wire packages coming from the ignition switch/coil cover. A two lead orange/black for I believe the switch which I have connected to the master harness. There is a second three conductor red/yellow/blue that I believe is from the ignition coils that there is no connector from the master harness. Should I assume it does not connect to the master harness any longer? This is a pain in the A#@!!!!! This is not my thing but I have all winter unless of course you want ot swing by and get errrr- done for me. As always any insight would be appreciated. Al
Did you remove that wire that was seperate from the original harness you were asking about the other day?

The ignition coil should be tied to that and should be blue red yellow and go straight to the ignition coil connector and not part of the new harenss (i.e the second wire you were asking about the other day). Also there will be another wire set running to the ignition module if not mistaken that is also not part of the harnes and it wil be for the crank postion sensor. From the igntion module will be a 3 pin connector (think it is red green black) that plgus into the master harness.

Look my DIY thread on post #5 second picture and you see the wire that is coming off the igntion module that goes back up the backbone that is not part of the new harness (if not mistaken you can see the Red Yellow wire at the connection in the picture). Here is the link

http://www.bigdogbiker.com/forums/how/30621-2005-pdm-install.html


The Orange and black should go to the key switch as you indicated if I recall right and that would come off the master harness.

The 8 pin connector should be the only one at that end and may be different color than what is hooking up due to possible variation from carb to efi, not sure. But it should be able to hook only way. If I recall right there was a sub block on the schematic that may have shown two different configuration depending it efi or carb or something along those lines.
 
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BigDogBro1

Made in the USA
I have the harness pulled through the backbone and started wiring. Firstly, the wire/pin location for the tach are not correct on the master harness--eight pin connector and two green wires in lieu of green/yellow as indicated in diagram and matched wire to tach. Secndly I have two wire packages coming from the ignition switch/coil cover. A two lead orange/black for I believe the switch which I have connected to the master harness. There is a second three conductor red/yellow/blue that I believe is from the ignition coils that there is no connector from the master harness. Should I assume it does not connect to the master harness any longer? This is a pain in the A#@!!!!! This is not my thing but I have all winter unless of course you want ot swing by and get errrr- done for me. As always any insight would be appreciated. Al
Why don't you give Bigdog PP a call and make sure you got the correct harness?
 
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