bd43's 07 Headlight Mod Part 2

[JeffrosFZ6]

Received my BD43 headlight mod wire this week and installed it today. I was going to make my own harness but could not find the headlight bulb terminal. It went very smooth except I stripped the negative battery cable bolt (its about 2 threads too short) and the wire is about 4 inches too long (just made a loop). Other than that it went excellent and works great!
I rate it...
Quality - 9
skill required - 7

The air box was extremely simple to pull off (ive heard horror stories). The hardest was prabably tidying up the wire under the front fairing (hard to reach).

All in all a great mod for $30.00 and 1 hout time.

[chimneydoc]

I'm just about ready to do the mod, but I have a few questions before I start. Do I have to remove any part of the faring to lift the gas tank out of the way?Does the air box and battery have to be removed to get at the coupler? Does the coupler that goes into the light socket just pull out or does it just twists out? Last of all, any good tips.

Thank You


Doc

[bd43]

It’s been a while since I did mine and some of the steps may be a little sketchy. Others who have done it recently can chime in. BTW, my bike is a 2007, so other years may be slightly different around the fairing area.

1. Make sure the fuel in the tank is less than half full.
2. Remove seat.
3. Remove left and right front cowling inner panel with 4mm Hex driver (Service Manual Pg 4-2)
4. Remove upper two tank screws with 5mm Hex driver (Service Manual Pg 7-1)
5. Lift tank pivoting on rear bolt being careful not to stress fuel pump wire harness.
6. Remove green connector to intake air temperature sensor (Item 3, Service Manual Pg 1-2)
7. With a pair of pliers, expand hose clamps at the tabs and slide down or along hoses. There are 4 of them, three at the rear and one on the right hand side of the air box. Wiggle each hose at the air box end to ensure they are loose. (Item 4, Service Manual Pg 4-3)
8. Disconnect starter relay connector above battery (Item 6, Service Manual Pg 4-3)
9. Disconnect negative battery lead from battery (Item 7, Service Manual Pg 4-3)
10. Disconnect positive battery lead from battery (Item 8, Service Manual Pg 4-3)
11. Remove the two 10mm bolts holding down the battery cover. Lift and move to the right hand side the battery cover (Item 9, Service Manual Pg 4-3)
12. Lift battery out of box and set aside (Item 10, Service Manual Pg 4-3)
13. Wiggle and lift the air box upward from the throttle body (Item 11, Service Manual Pg 4-3)
14. Remove the two 10mm bolts holding down the battery box located just forward of the battery cover holes (Service Manual Pg 4-4)
15. Lift and slide rearward the battery box. There are fingers on the sides and near the bottom of the battery box that must clear by lifting upward to slide the box rearward.
16. The connector can now be found hidden in a rubber boot inside the frame.
17. Continue with the harness install.

For putting everything back together, reverse the removal procedure.

When putting the air box back onto the throttle body, ensure all the rear hoses are aligned over their respective ports and that the box is over top of the throttle body openings before squarely wiggling and pressing down on the box to re-install. I did this with the top of the air box off and the air cleaner removed. It’s not mentioned in the service manual but I did it this way and maybe that’s why I didn’t have any trouble getting the air box back on. Doing this you can clearly see if the box is in alignment with the throttle body ports by peering down through the box.

If you study this picture closely, you can see the green air temp sensor connector off to the bottom right, the 3 rearward hoses with their clamps slid down them, the hose off to the right hand side with it's clamp slid along it, the battery box top hanging off to the right hand side of the frame, and the battery box with ignition coils attached moved rearward closer to the throttle body intakes. In this picture the handlebar connector has been disconnected and I pulled it out of the frame to take some pictures but this is not necessary.

[JeffrosFZ6]

Mine is a 2006 and the inner panels are 1 piece (small section do not come out as the 2007's do).

so... I removed the long bolt at the rear of the tank, then removed the 2 bolts at the front of the tank. Then slid the tank back (pulling away from the front cowling) then lifted up. Then reinstalled the rear tank bolt, pivot the tank up and bungie corded to stay up.

make sense? I should of taken pictures when I did mine.

[devol]

Did my Mod yesterday. It took me 30 mins total. BD great job on the write up and pics !!! Thanks again!!!

[brad81987]

Forgot about this thread. Did this a week or two ago. Great mod, amazing craftsmanship and engineering on BD43's part. Mod is pretty easy. Getting the air box on and off is actually quite simple. I struggled the most with getting the connector out of the boot and disconnected. Aside from that it was smooth sailing. While I was at it, I took the opportunity to wire up and accessory block, similar to what Fred did in his video.

[08fz6]

did mine a week or so ago, took me 30mins total and that includes going back and finding each tool I needed. Was pretty easy! I think it took longer routing and zip tieing the wire to the bike than it did getting to the plug....

[hot4teach]

Does the factory green wire in the plug come directly from the swicth on the bars?

[bd43]

Originally Posted by hot4teach

Does the factory green wire in the plug come directly from the swicth on the bars?

Yes, you can see the green wire at the end of the connector in the picture of my post just above. I pulled the connector from the frame and laid it on top for a better shot.

[bullofspadez]

Received BD43's wire and was not sure if i was up to the task and was going to put it off until winter. But I kept looking at the pictures and psyched myself up and 2 hours later(it was hot in the garage/water breaks) it was done. I can only say one thing...So easy a caveman could do it. Daryl's craftsmanship is amazing and made this mod very clean.

My notes on this mod. Just take your time and separate each piece you take off. I used 3 cardboard boxes and just put the screws with the pieces they went with after taking them off. Taking off the air box is by far the trickiest part. Well more for big fingered people. A longer allen wrench would have helped to get those clamp screws loosened. I had one that was very tough to get an angle on.

Thanks BD