PDM install question

[Long Island]

I received my PDM yesterday and I plan to install it this week. Other then the usual of double checking all the connections and shrink wrapping anything that can be along with dielectric grease and making sure that nothing is located near a possible kink area or heat. Does anyone have any first hand knowledge or insight of things that could help me while I do this swap? I already read the "how to" post of the install on this site. Just was wondering what some of you may have ran into to help me to not make the same mistakes. Y'all say that it takes about 4 hours. I'm giving myself all day :lol: . Minus a midday break from the heat.
PS- Does anyone know what size (I guess allen key) you need to back off the front brake set screw that's holding the sensor for the PCB? Is that in the hole right next to where the sensor goes in? Sorry, not only am I a newbie when it comes to working on bikes, I also don't have much light in my shed. That's why I'm doing the install outside and the need for a midday heat break. Wish me luck :up:

 

[bearman]

read this about the right hand control PCB.
Post #1
Under Tip of the Week #3
read #4 and #5
http://www.bigdogbiker.com/forums/technical/11183-night-trains-tech-tip-week.html

The whole post has some good general wiring info.

Now that I think about it, I don't think you will need to remove your brake sensor to install the PDM.

 

[Long Island]

Normally you wouldn't but mine tested as bad and I have the replacement ready to go in, I just didn't see how to get the sensor out. Thanks

 

[Fibersnake]

I received my PDM yesterday and I plan to install it this week. Other then the usual of double checking all the connections and shrink wrapping anything that can be along with dielectric grease and making sure that nothing is located near a possible kink area or heat. Does anyone have any first hand knowledge or insight of things that could help me while I do this swap? I already read the "how to" post of the install on this site. Just was wondering what some of you may have ran into to help me to not make the same mistakes. Y'all say that it takes about 4 hours. I'm giving myself all day :lol: . Minus a midday break from the heat.
PS- Does anyone know what size (I guess allen key) you need to back off the front brake set screw that's holding the sensor for the PCB? Is that in the hole right next to where the sensor goes in? Sorry, not only am I a newbie when it comes to working on bikes, I also don't have much light in my shed. That's why I'm doing the install outside and the need for a midday heat break. Wish me luck :up:

There is no reason to take off your sensor of any of the Hand Control switches. The whole PDM harness will just plug into the existing connectors once they are disconnected in the old wiring harness. The one for the Hand control run through the handle bars and a simple connection for the wire in the harness. No need to remove or mess with any switches.

Advise, take your time, have a multi-meter handy, get everything installed, double check and before finishing up and tiddying up the wiring into the electrical cover and seat area, recommend that you test everything. Oh and when disconnecting the battery, remember negative first on removal, last on install.

 

[Advodka]

Took me alittle longer than 4 hrs. (10hrs to be exact) Had to fix alot of scabbing done before I bought it and fitting it all under the covers was a good bit of it. Take your time double check every connection and you should be fine.:2thumbs:

 

[Long Island]

There is no reason to take off your sensor of any of the Hand Control switches. The whole PDM harness will just plug into the existing connectors once they are disconnected in the old wiring harness. The one for the Hand control run through the handle bars and a simple connection for the wire in the harness. No need to remove or mess with any switches.

My PCB (the start/run board) has the front brake sensor hard wired onto it. The wire goes into a little hole and is held in place with a set screw to work off of the front brake handle. So, I need to get it out to put the new one in.

 

[olddog58]

Did it all work? My PDM on 08 K9 EFI had one significant error on the wiring diagram. It showed the low fuel relay plugged into Power, which gave me a battery drain. the fix was to re-wire the relay to a switched wire. But the diagram definitely shows it wired directly to power.

 

[TCALZ06]

I had some problems with the diagram too but I had one of the original kits that I had sitting on my self for a couple years.

My advice is to take the harness and test every wire before you install it. We found a bad one after we put it through the frame.
We had another bad one that we found after we had everything else working.
Somewhere in the harness it lost its ground so I had one turn signal that worked and one that didn't. This bad ground also caused the headlight not to work.
Also, lay the harness out and make sure you know where every wire goes and maybe mark them. I think it was a major ground we had hooked up wrong

As far as the time to do it....... well mine took a lot longer than 4 hours.
Do yourself a favor and check the wiring out first

 

[07bigdog]

I also installed a older PDM kit and it has a faulty HCI. Ignition module light goes out as soon as you hit the start button. Had to buy another complete harness and haven't installed it yet. I've now got with shipping and brokerage fees almost $1500 in this kit.

 

[TCALZ06]

Thats sucks. Big dog performance told me if I sent them my harness they would upgrade it for like $300 to the new version and it would have another year warranty.

I only have a couple hundred miles on it and everything is working so I don't want to pull it apart again. I just got the rebuilt trans in so I'm kind of tired of working on it.

 

[07bigdog]

They also said they could try and fix it but not positive for around $300. Then Bob told me that the new harness is more refined and everything is cut to lenght making the wiring alot shorter than the old harnesses. I ended up soldering in some resistors to get the ignition module to work. May switch it over in the winter.

 

[Fibersnake]

My PCB (the start/run board) has the front brake sensor hard wired onto it. The wire goes into a little hole and is held in place with a set screw to work off of the front brake handle. So, I need to get it out to put the new one in.

Yes that is true, but I am confused! Are you trying to change out the PCB board or put in the PDM, for the harness for the PDM connects to the JST connector under the fuel tank to the smaller harness that go to the Hand Control.

When you put the PDM in, you are only changing out the Main Harness and the Power Harness of the old EHC, you are not changing out all the little sub harness to Hand controls from the main, or to say like headlight, taillight or for the matter even the one going straight to the ignition module to coil (small separate three wire if not mistaken that is not part of the main harness connected to the EHC).

Anyway still confused why you would be messing with the sensor at the hand control or even the PCB board for a PDM change out!

On the EHC to PDM change out, bit of advice, start at the EHC and disconnect the main harness (the one that run up the backbone), when you get to a connector, disconnect the plug fro the harness but leave the wire that go from that plug to where ever alone. You will reconnect the new harness that comes with the PDM into those connectors. The same would be for the power harness (the other one on the EHC that goes battery, et)-the PDM will have one harness that covers the old two harness of the EHC).

If you want to be very cautious, once you remove the old harness from the EHC and the EHC, you can take your trusty multi-meter and check all those connectors that were disconnected from the old harness which remain, and check for any shorts, grounds, breaks and continuity, if all good or if there was no problem, with such, leave those sub-components alone and just reconnect your new PDM harness to the appropriate JST connectors and fire the baby up and go for a ride.

 

[Long Island]

Yes. I am changing both. Just couldn't find the set screw for the front brake sensor. I see the sensor wire going into a hole by the brake lever. Is it the hole right next to it? What tool does it take to loosen the set screw?
Ok, I found it. Wasn't really that hard to see. I just needed better lighting