End of my rope-Duel Headlight

[zoomman]

I have the harness from Bikerdude. I have everything up to the aribox removal done. I'm quite honestly afraid to go any further. Is there any other way to complete this mod without removing the airbox? I had to remove my upper cowling due to the accident and everything is exposed now, so if anyone has tried this and can help...please!!!!

Thanks

 

[nlheikki]

You have to remove the airbox to get to the correct connector.

-Nick-

 

[madmanmaigret]

if you are nervous about losing stuff take some pictures of it after everything you remove that way if you feel lost you can take a look at the pics and see what you are forgetting. Once you have it done you will prob. be like "wow, that was easy"

 

[Hellgate]

if you are nervous about losing stuff take some pictures of it after everything you remove that way if you feel lost you can take a look at the pics and see what you are forgetting. Once you have it done you will prob. be like "wow, that was easy"

I like to lay out the parts in the order to took them off. Then I just put them back on in reverse.

The air box isn't too bad.

 

[armystrong]

I was nervous too...but just go for it! Pay attention to what you remove and then just put it back the same way you take it off.

 

[FZ1inNH]

Take a pic, print it in B&W, then as you take out parts, match them to the pic on the floor. It's not many parts to take out. It just looks worse than it really is.

 

[jamesfz6]

Don't give up.

 

[madmanmaigret]

I like to lay out the parts in the order to took them off. Then I just put them back on in reverse.

The air box isn't too bad.

this works if you dont have too many parts... air box it will work but for whole motors, transmissions, transfercases, axles, wheels, brakes, and rear ends all at once it gets to be a mess...... especially if it is going to take six months before it is all put back together...

but it is always worth it in the end.:rockon:

 

[Denver_FZ6]

No new advice except to reinforce what's already been said:

• Yes, airbox has to go.
• Take pictures as you go from different angles. A digital camera is great because you can immediately review pics during reassembly.
• Take your time! Get a look at how parts fit together BEFORE you remove them.
• Reread BD's original how-to post. Everyone will come across their own 'gotchas' but he lays a great foundation on how to do it.

Took me several hours when I did it, as I really took my time and tried to understand how things fit. Could probably do it in an hour now.

 

[zoomman]

THANKS TO ALL WHO RESPONDED!

That's what makes this site so special...seriously!

Ok, almost done. Got the airbox off, every thing's all set to put back. just one thing...WHAT AND WHERE DOES THE WHITE PIN CONNECTOR LEFT OF AIRBOX GO? I can not for the life of me remember.

I picked the wrong 6 months to stop smoking the wacky...lol

 

[madmanmaigret]

do you have the service manual? is it in there?



see, if you would have taken pics.........


ok ok off my soapbox

 

[zoomman]

NEVERMIND!!! Found it.:Im With Stupid:

Thanks again everyone...I'll post the final pics later if everything goes well.

 

[zoomman]

I don't say this very often, but, AWESOME!!! Mission Completion...tested and working perfectly.

Thanks again everyone for your help.

 

[zoomman]

Pics of Duel Head Half Naked

Great day off to spend on doing Mods. Waiting for my upper Cowl to come so I can install. Frame sliders and touch up paint are also on the way.


Thanks again to those who helped!

Pic#1, low
Pic#2, high
Pic#3, nekkid

 

[nlheikki]

Re: Pics of Duel Head Half Naked

Good work. The mod definitely pays for itself, especially riding at night.

-Nick-

 

[OkieDavid]

Actually.....the air box may NOT have to go. I was able to remove the battery box (2007 model) by simply removing the air box hold down bolts and applying pressure to the air box to slide the battery box out. It was a tight squeeze but it did come right out. Dont get hung up on removing the air box just because all the instructions you've read say to....The battery box is/was the hang up, focus on what it takes to get it out of the way. Note: I didn't use BD's harness but I did tap the exact same wire at the connector so it's kind of a moot point as I was at the same place.

 

[brad81987]

I'll be installing my BD harness sometime this week so thats good to know, thanks.

 

[zoomman]

Actually.....the air box may NOT have to go. I was able to remove the battery box (2007 model) by simply removing the air box hold down bolts and applying pressure to the air box to slide the battery box out. It was a tight squeeze but it did come right out. Dont get hung up on removing the air box just because all the instructions you've read say to....The battery box is/was the hang up, focus on what it takes to get it out of the way. Note: I didn't use BD's harness but I did tap the exact same wire at the connector so it's kind of a moot point as I was at the same place.

I actually found that the same was true after I pulled the airbox off. Also the rubber boot that contains the plug is towards the front of of the bike. I was looking on the side, instructions for pulling the airbox off lead me to believe that it was near or under the AB.

 

[Doorag]

I actually found that the same was true after I pulled the airbox off. Also the rubber boot that contains the plug is towards the front of of the bike. I was looking on the side, instructions for pulling the airbox off lead me to believe that it was near or under the AB.

I tried to do this before, but didn't have a long enough allen-key to get the air box off. I'm very interested in not taking it off unless necessary. There seem to be a lot of things holding the battery box down. Is it really that easy to get it out?

 

[zoomman]

I tried to do this before, but didn't have a long enough allen-key to get the air box off. I'm very interested in not taking it off unless necessary. There seem to be a lot of things holding the battery box down. Is it really that easy to get it out?

Follow all the instructions and pull take out all the bolts. Just before you get to the Airbox, try to slide the battery box towards the rear of the bike. You may have to pull the airbox forward slightly. I was really nervous given my mechanical skills, but now that I completed this mod it's given me more confidence. Taking the airbox off is really not a big deal. It helps to have it out of the way so that you can just slide the battery box out and get to the rubber boot easier.

Also, like others have stressed in this post...take pictures if you need too. Also Bikerdude has additional write ups that were very helpful in the howto's section.