2004 Big Dog Redesigned EHC Installation Instructions
Part # 170-000082-00 EHC Adapter Board
Part# 176-000003-00 EHC, programmed, Carbureted
Part# 173-000035-00 EHC Terminal Kit
Part# 260-000096-00 Template EHC hole relocation
Get your tools ready
Open Beer Here
Drill with #10 Bit
Battery Wrench
3/8 wrench
5/16 Allen Wrench
Wire Pliers (Strippers and Crimpers)
1. Remove Seat (If you are having trouble at this step STOP and take it to your dealer):bang:
2. Disconnect Battery, Negative first then Positive
3. Remove EHC Harness Connector
Thats the Big wire bundle on top
4. Cut tie wires as needed to remove wires
A. Disconnect Horn Grey wire
B. Disconnect Compression Relief (Yellow)
C. Disconnect Starter wire (Green)
Instructions didnt say to remove the EHC all the way but do it Do it now
5. Remove rear 5/16 allen screws (one on each side) from each fender strut
6. Loosen but do not remove front 5/16 allen screws front of strut (I suggest loosen front ones 1/4 turn)
7. Raise fender up and remove 3/8 nuts retaining the EHC
(My old EHC had no nuts must have been a female EHC or a Steer)
8. Lower fender to tire
9. Possition paper template when old EHC was
(far back as possible without hitting fender)
10. Drill out holes with a 3/8 bit
11 The holes will fit inside old holes dont use old holes
12 Place new EHC in place
13 Raise fender and put washer and nut on
14 Tighten nuts to max of 15 in lbs
15 Lower fender and put allen head screws back in tighten to 25 foot lbs
16. Route each wire to its connection point and remove excess length with wire cutters
Meassure twice cut once
17 Crimp end terminals to wire
RED (Possitive) Round metal
Black (Negative) Round metal
Grey (Horn) Red clip
Yellow (Compression relief) Red Clip
Green (Starter) Blue Clip
18 Route Grey wire and connect it to the horn
19 Route Yellow wire and connect it to starter
20 Route Green wire and connect it to the Starter (Hate that connection)
21 Connect red wire to Battery
dont forget to connect other two wire also at this time to Possitive side
22 Connect Black wire to battery
Dont forget the other wire too
23 Connect possitive side first
always negative off first on last
24 Remove connector on neutral switch (Top of tranny push aft and slides off)
Note White, Green, and Black wire
CUT THE WHITE WIRE
:2thumbs: ONLY CUT WHITE WIRE
25 Reconnect Neutral switch terminal
26 Remove EHC Connector dust cap
27 Connect harness to EHC to Complete Installation
Part # 170-000082-00 EHC Adapter Board
Part# 176-000003-00 EHC, programmed, Carbureted
Part# 173-000035-00 EHC Terminal Kit
Part# 260-000096-00 Template EHC hole relocation
Get your tools ready
Open Beer Here
Drill with #10 Bit
Battery Wrench
3/8 wrench
5/16 Allen Wrench
Wire Pliers (Strippers and Crimpers)
1. Remove Seat (If you are having trouble at this step STOP and take it to your dealer):bang:
2. Disconnect Battery, Negative first then Positive
3. Remove EHC Harness Connector
Thats the Big wire bundle on top
4. Cut tie wires as needed to remove wires
A. Disconnect Horn Grey wire
B. Disconnect Compression Relief (Yellow)
C. Disconnect Starter wire (Green)
Instructions didnt say to remove the EHC all the way but do it Do it now
5. Remove rear 5/16 allen screws (one on each side) from each fender strut
6. Loosen but do not remove front 5/16 allen screws front of strut (I suggest loosen front ones 1/4 turn)
7. Raise fender up and remove 3/8 nuts retaining the EHC
(My old EHC had no nuts must have been a female EHC or a Steer)
8. Lower fender to tire
9. Possition paper template when old EHC was
(far back as possible without hitting fender)
10. Drill out holes with a 3/8 bit
11 The holes will fit inside old holes dont use old holes
12 Place new EHC in place
13 Raise fender and put washer and nut on
14 Tighten nuts to max of 15 in lbs
15 Lower fender and put allen head screws back in tighten to 25 foot lbs
16. Route each wire to its connection point and remove excess length with wire cutters
Meassure twice cut once
17 Crimp end terminals to wire
RED (Possitive) Round metal
Black (Negative) Round metal
Grey (Horn) Red clip
Yellow (Compression relief) Red Clip
Green (Starter) Blue Clip
18 Route Grey wire and connect it to the horn
19 Route Yellow wire and connect it to starter
20 Route Green wire and connect it to the Starter (Hate that connection)
21 Connect red wire to Battery
dont forget to connect other two wire also at this time to Possitive side
22 Connect Black wire to battery
Dont forget the other wire too
23 Connect possitive side first
always negative off first on last
24 Remove connector on neutral switch (Top of tranny push aft and slides off)
Note White, Green, and Black wire
CUT THE WHITE WIRE
:2thumbs: ONLY CUT WHITE WIRE
25 Reconnect Neutral switch terminal
26 Remove EHC Connector dust cap
27 Connect harness to EHC to Complete Installation
