bd43's 07 Headlight Mod Part 2

[Nelly]

Originally Posted by Numpty

Have you been talking to toolkit????? LOL

There was a warning posted. Mr Guinness guts lo.

[nlheikki]

I received my wire harness from bd43 tonight and have installed it. The instructions were great and the install went very smooth. I would say the install took about an hour and took 1.5 hours to remove and re-install the dang airbox. If it wasn't for the airbox, I could have gone for a ride tonight.........GREAT PRODUCT though!!!

[irishstout]

I received Daryl's wire harness for my 2004 FZ6 on Friday and everything installed smoothly today. Excellent product Daryl and great instructions!!!! I also installed a battery tender and new battery since I had everything taken apart. Now I also can keep a charge between rides.

I would highly recommend this harness to anyone that has considered this!

It wasn't difficult to install especially with the great instructions, but I would make sure you have the following:

5/32 & 3/16 Hex Wrenches. **You need the 5/32 to be at least 4/14" or longer to get to the bolts for the airbox and a good eye.

Phillips head screwdriver

Long Nose (curved if possible) pliers for the hose connections on the airbox

Bungee cord to hold the tank (make sure there is less than 1/2 tank of gas as well to prevent overflow)

10mm socket wrench (with extension)

If you have all of these items, it shouldn't take much longer than an hour max.

Good luck and safe riding!

[Nelly]

Originally Posted by irishstout

I received Daryl's wire harness for my 2004 FZ6 on Friday and everything installed smoothly today. Excellent product Daryl and great instructions!!!! I also installed a battery tender and new battery since I had everything taken apart. Now I also can keep a charge between rides.

I would highly recommend this harness to anyone that has considered this!

It wasn't difficult to install especially with the great instructions, but I would make sure you have the following:

5/32 & 3/16 Hex Wrenches. **You need the 5/32 to be at least 4/14" or longer to get to the bolts for the airbox and a good eye.

Phillips head screwdriver

Long Nose (curved if possible) pliers for the hose connections on the airbox

Bungee cord to hold the tank (make sure there is less than 1/2 tank of gas as well to prevent overflow)

10mm socket wrench (with extension)

If you have all of these items, it shouldn't take much longer than an hour max.

Good luck and safe riding!

Its Great isn't it. I am amazed at the difference it has made with night time riding.

Nelly

[bond2penny]

I just want to add what a great mod this is, with brill instructions, made up the harness and fitted Sat afternoon and had it fitted and back together by dinner,

Many Thanks

[goran21220]

I need help with removal of battery box!The two bolts that are holding it wont come of!!!I'm turning them and nothing!I'm trying to get to the connectors to instal BD harnes.Anybody experienced the same problem?Its a brand new bike,just bought it couple of months ago!Any ideas how to remove them?

[bd43]

Hi Goran;

I'm not sure what to say since I did mine before winter. It should just counter-clockwise spin right off. These are metric bolts so you are using metric sockets? The reason why I ask is if you are using imperial sockets it might seem to fit over the bolt initially, but when you add some torque to turn them, the socket is just rounding the bolt heads a little and turn around them instead of turning the bolt itself.



In the above picture, the battery box bolt is the one just above the same one in my hand. The hole to the right of the bolt is for the cap of the battery box, I think.

[goran21220]

No.i've tried several different sockets,that's not the problem.I was turning the bolts and i could feel quite resistance but they were not going anywhere! I dont know whats underneath that plastic and what the bottom part looks like.I tried unscrewing the bolts on the sides that are holding the same part thinking i could take the whole thing out but it's stuck,like its glued from underneath! i know it's wierd i have a problem with both bolts,i would think that who ever put them on used too much force and now when im turning them im actualy turning the bottom part as well which is i assume implemented in the plastic.Any ideas,i'm out of them! Excuse my spelling,english is my second language!
By the way,excelent product,very well made!!!

[bd43]

Here's a picture of what lies underneath.



It's like a blind nut recessed into the plastic or frame. Judging by the length of the bolt, it is possible that you may have applied too much pressure pushing down on the socket as you loosened it thereby pushing the blind nut downward and out of it's slot so once it clears the frame, it's now just spinning in mid air. Is the bolt loose and able to move up and down a little? If this is the case then lift bolt with fingers while turning. When the blind nut gets into alignment with its slot, you should see more bolt exposed. Pull up until you have good resistance and undo the bolt the rest of the way by hand. All I can think of at the moment. Try that.

[goran21220]

I wish it was loose!Who ever put this together use too much torque...I'll give it a try again tomorrow.I cam't belive they did that to both bolts! Thank you for trying to help!