PDM 05 Mastiff

[dmouse]

After a long wait i received my PDM kit today and looking at the paperwork trying to understand everything before i dive in it states that, the ignition module relocation kit must be installed with the battery tray part number 173-000105-00 as part of a recall #06v-301. does any one have any info on this i have looked on the BDM site and there is little or no info just prices. do i need this part i do not even know what it looks like or if my bike has had this recall fixed or not any help or info would be appreciated. as i have everything keyed up for my motor to be done and new paint once this PDM kit is installed.

thanks and regards to all

dave

 

[Macdwn]

Im pretty sure any dog running a 250 has to have the battery tray replaced. It kicks the price up a hundred bucks or so.

 

[dmouse]

ok thanks for your reply, so the part is the the battery tray which is great as this came with the PDM kit, so today i will start to install it and hopefully kill all of the EHC gremlins once and for all.

thanks again and the very best of regards

Dave

 

[dmouse]

ok so i have done the battery tray and all of the wiring there is all good, took the old loom out of the backbone it wasnt easy but a bit of jiggling got it out without any damage, took the new PDM loom and tried to tape it all up so as no two connectors were to close together so as to jam it in the frame, i threaded some wire down from the top and taped it to the loom and tried to pull it all back to the top to connect up the speedo and handle bars. but no matter what i do the loom gets jammed up and i can only get a couple of inches of the loom through it is jamming inside the backbone, so i have pulled the whole thing back out and staggered the connectors even more but its no better, and something in the backbone is very sharp and cutting the tape around the loom. so i am stumped and thinking about splitting the loom into separate leads threading it all through and re taping and re heat wrapping it all separately as best as i can does anyone have any ideas any thing would be appreciated at this moment before i cut it all up

regards

dave

 

[Macdwn]

I know when I helped raywood do his pdm I used a pic set to individually pull each connector through. It took a little time be we got them all through without cutting it.

 

[dmouse]

I know when I helped raywood do his pdm I used a pic set to individually pull each connector through. It took a little time be we got them all through without cutting it.

thanks for the info but there is just not enough room at the opening to feed the wires through, i have staggered them as best as i can and even tried folding some back to give me more room but the loom is getting stuck on something in the tube and just will not move, and on pulling the loom back out its snagging on the lip of the tube and cutting the plastic coating off and causing damage, its a pain that i cannot see what is causing it, i have tried a piece of wood dowel and there is a blockage in the backbone about 4 inches in i can get past it with a bit of wiggling but its a tight fit. so i think i will have to split the loom and do it all separately and re-tape and shrink wrap it all again as best as i can i just wish that i had got a shop to do it now o well its a learning curve i suppose. many thanks for your advice and help i will let you know how it turns out when i get it all back together.

many thanks and regards

dave

 

[Slider]

I used a piece of string from my weed trimmer, staggered the wires, electrical taped them and pulled them through. Maybe try some wire pulling lube for conduits. Home Depot has it

 

[dmouse]

I know when I helped raywood do his pdm I used a pic set to individually pull each connector through. It took a little time be we got them all through without cutting it.

thanks for the info but there is just not enough room at the opening to feed the wires through, i have staggered them as best as i can and even tried folding some back to give me more room but the loom is getting stuck on something in the tube and just will not move, and on pulling the loom back out its snagging on the lip of the tube and cutting the plastic coating off and causing damage, its a pain that i cannot see what is causing it, i have tried a piece of wood dowel and there is a blockage in the backbone about 4 inches in i can get past it with a bit of wiggling but its a tight fit. so i think i will have to split the loom and do it all separately and re-tape and shrink wrap it all again as best as i can i just wish that i had got a shop to do it now o well its a learning curve i suppose. many thanks for your advice and help i will let you know how it turns out when i get it all back together.

many thanks and regards

dave

 

[dmouse]

ok got the loom through hopefully all is good, the problem i think was that the connections are not staggered enough and the wires were bending back on themselves and causing the blockage and making life hard for me. so its all through now and hopefully without any damage just do not have enough time at the moment to connect everything back up. but i will continue to post until its all done and hopefully fires up without a problem. but just my 2 cents worth i wish that i had gone for a simple Harley style wiring system with less wires it would of been as easy as. but the wife wouldn't be happy if i was to throw NZ $1000 worth of wires into the bin now my life would be hell.

many thanks and regards

Dave

 

[dmouse]

having missing wire problems any help would be appreciated i know im stupid but im really trying here guys

it appears i do have the relocation kit already installed, but on my ignition module i have three leads that come out of it but only two from the PDM harness that connect to it, the PDM harness is missing the coil leads for the cylinders ( blue/red/yellow) all i have on the PDM is brown/white and red/green/black. and at the top end where the PDM main harness comes out of the between the gas tanks i have two leads with red/green/black that have nothing to connect to ?? i have everything else connected except the single stripped red/orange wire.

please help it just does not make any sense ???

regards

David O`Neill

 

[dmouse]

Ok with the help of Fibersnake and others from the forum, i now have my bike all back together and tided up and running like a she was meant to, i do not have to worry about losing power to my speedometer and idiot lights or my four way flashers coming on, on there own so people riding or driving behind or in front get an idea of which way i am going to turn. my thoughts on the PDM its a good replacement and does the job really well, but the paperwork needs some more info on the coil wires as this threw me out badly and wasted a lot of time that i could of used elsewhere. i think that the system could be cut down a lot more as its far bigger than the original bdm harness and is quite tight trying to fit everything in nice and tidy. but it does the job it was made for and so far i am very happy with it. now i am going to get my enigine work done and a new coat of paint for the upcoming summer and enjoy her i will post some pics of before and after once she is all sorted.

once again many thanks to all of those that helped me out with this i enjoyed doing the install but without the help given from here i would still be sat wondering where the coil wires were. many thanks and the very best of regards to you all :2thumbs::up:::choppersmiley::choppersmiley:

dave