| Author | Message | ||
     Brinnutz |
Court, I'm overhauling my bike, and I found a problem. I was trying to replace just the taillight harness, which should be just the taillight connector and a connector to plug into the main harness. The 2002 M2/M2L Factory Service Manual shows that this piece exists. So, I went through and started cutting off the wire loom, and got to the point where a connector should be, but the harness seems to just tie into the main harness itself. See, I wanted to replace the harness so that I could get a stock bulb mount on since it had an integrated light on it. Now I have a cut up harness with tons of loom missing because the Factory Service Manual told me it was there. I can't afford a new main wiring harness, as it's showing in at $330: http://chicagoharley.com/shop/product_info.php?pro ducts_id=4580 But my thing is, the dang manual told me that it was there, and I followed it, but it doesn't exist! I'm trying to keep the bike as easy to return to stock as possible in some aspects, so that's why I was trying to replace the taillight harness in the first place! This is a pic of what the drawing in the FSM pretty much looks like:  I guess what I'm asking is if I should call the factory and speak with someone about this issue? Heck, the connector may just be farther up in the main harness, but then I'd have to cut more of the loom off exposing all of the wires, but I don't feel a connector anywhere under the loom! I'll try to scan in a copy of the page in the FSM that shows this as well. Thanks a ton! Wilson PS - I pm'ed you also. =) | ||
| Court |
Not sure I quite understand . . . . but I have the manual, let me know what page you are looking at. | ||
| Brinnutz |
Court, the page in the FSM I am referring to is 7-53 (lower right corner...the number at top and bottom always confused me for some reason). In the upper right corner, is the picture of the taillight and the harness itself. The left end with all the tiny, loose connectors is where the taillight and turn signals connectors are (funny thing, the 2002 had a different style taillight connector too that looked nothing like the loose wires). Then on the right side of the harness is where the 8 pin connector I was trying to locate is. Well, it's not there. Where that connector is supposed to be, is where the loom from the main harness and the taillight harness become intertwined and you can tell there's obviously no connector beneath the loom. So, seeing this picture, and knowing I wanted to replace the small taillight harness, I started cutting the loom from the taillight bulb end, towards the connector since one was not readily visible (and there was a hard spot under the loom near where the ECM mounts, so I thought that might be it). Well, I get to that spot in the taillight harness and it's not a connector, just some thick plastic around two single strands of black wire. So that's the problem, according to the FSM, there is a connector to disconnect the taillight harness from the main harness, but on my bike, it is nothing like that, it's ran directly out of the main harness so I can't replace the piece I have no cut the loom off of when I assumed it was just like the FSM showed me. Thanks again... | ||
| Brinnutz |
Here are pics of the manual:  Close up of the pic:  Now, the actual taillight harness on the bike (see it running all the way up the tail) :  Now this is where I am having the issue..according to other Cyclone owners, this is where the connector, as shown in the manual, should be located. But my wires (yes, the loom is removed now because I was looking for it), go straight into the main harness, no connector. If there is one, I'd have to cut the entire harness loom to get to where ever it is. The taillight harness is the black skinny one coming down from the top left out of picture.  | ||
| Court |
I'm afraid I'm not much help on this one as I can't find my 2002 manual to save me. I did look at the 2001 parts manuals though but the page (91) that is supposed to have the main wiring harness is actually the muffler. It looks like the best thing to do would be to either put new connectors on the end of the existing harness or (if you've already cut some of it) cut the old harness about 8" shy of the main loom and build a new harness going to the back. | ||
| Brinnutz |
Court, the black stuff, the interwoven loom stuff, is not there anymore since I was looking for the connector, so now it's a bunch of bare wires, and I can't just replace the black outer loom/wire covers since its all attached to the main. Can you see the pics I posted above? The page is from my 2002 service manual. The manual doesn't have a pic of the main wiring harness, next to where it is listed, is says (Not Illustrated). (Message edited by brinnutz on April 03, 2009) | ||
| Court |
Yeah . . . I was looking for the parts manual to see if the brake light harness was a separate service part. Another idea would be to rewire and replace the WIRE LOOM.  | ||
| Brinnutz |
I could do that...was looking for a way to have the stock look again, not only with the loom, but with the taillight connector that isn't there anymore since there was an integrated LED light and the stock bulb connector is cut off. That's how the whole project started. So, there is no "replacement" connector for the 2002 M2 taillight connector, as it's all part of the main harness, but the FSM told me different. damn. | ||
| Gowindward |
Wilson Look here for wire sleeve. It's cheap and the "wrap around" kind is a breeze to use on a job like yours. The stuff is like a spring and really stays on well, and then a few zip ties along the length and it's golden!! http://www.mcmaster.com/#sleeving/=1a8xrg Loren (Message edited by gowindward on April 03, 2009) | ||
| Brinnutz |
Ok, the loom isn't the only problem.. Its the taillight bulb connector on the 2002's. I'll see if I can't get someone to post a pic, because it looks nothing like the one in the 2002 FSM. | ||
| Buell920 |
IS THAT A TOILET SEAT UNDER THE BIKE? | ||
| Brinnutz |
Yeah, that's my shop chair. Custom made. It was a leftover in an apartment garage I rented. I cleaned and disinfected it and it's right at the perfect height. Beats having to buy a shop stool! | ||
| Court |
Didn't realize we had the same post going in different areas. Posted on Friday, April 03, 2009 - 02:14 pm: -------------------------------------------------- ------------------------------ Court... I'm the same guy in your forum asking you. The service manual told me something that didn't exist on my bike so it informed me WRONG! Court Posted on Friday, April 03, 2009 - 02:26 pm: -------------------------------------------------- ------------------------------ So what's the question? How to fix it? I thought that was the discussion we were having over there? If the manual is wrong (and lots of them are, as they are typically done before the bike is completed) the first page is a "tear out" to send to "Technical Publications" to let them know. I try, every year, to go through and look for stuff. In the case of the M-2, I noticed, while looking for your stuff last night that the page (91) in the 2001 manual that is SUPPOSED to be "Wiring Harness" is actually the muffler. That's reason that they put all those disclaimer and stuff in there. Did you cut all this stuff off BEFORE you noticed there was no connector? Court Posted on Friday, April 03, 2009 - 02:27 pm: -------------------------------------------------- ------------------------------ I guess my question is . . . . are you wanting an ANSWER (you question to me, which I answered was "what do I do about it?") or are you thinking that they should give you a wiring harness? | ||
| Brinnutz |
Well, the manual told me one thing, so I cut the loom looking for the connector. I felt hard areas under the loom that did feel they could possibly be a connector. Oh well. | ||
| Court |
Where is it cut to now? It **looks** in the above photo like it extends nearly all the way to the tail light? I am not seeing the tail light harness as a separate part as it has no part number. I'd interpret the above to mean that the plug is at the other end of the harness. Can it be spliced? You're thinking . . .according to other Cyclone owners, this is where the connector that someone, perhaps a prior owner, changed the harness? Are you the original owner? I can check and see if the harness is still available and also, if you want to send me your VIN, if yours had anything done differently when it was built. | ||
| Brinnutz |
Yes, I know on the earlier models 97-98, there was a disconnect, just like there is on the X1's, so just the taillight harness could be unplugged. The picture was taken prior to me doing any of the loom cutting. I took it to reference in case I didn't find the connector, the spots the I found under the loom were just thing plastic things around single wires, no idea what they were for. I'm just trying to get it back so I can have the stock taillight connector back is all. It seeming impossible now. | ||
| Davegess |
What does the parts manaul tell you? Those are often better for this kind of things than a service manual. | ||
| Court |
I have bad news and good news . . . . The "bad news" is that I tired the "detrimental reliance" (a legal doctrine I have had some experience with) on the Service Manual and that went nowhere. The manual is full of "look before you cut" warnings and "subject to change" provisions. The "good news" is that there are 4 of the Y0200.01A3 harnesses in stock. Perhaps worthwhile to record you experience with the manual on the form and send it in.  Your should find that form in the front of your SERVICE MANUAL. If not, just print that one out and change the description to: 2002 Cyclone M2 Service Manual 99491-02Y | ||
| Ratbuell |
It's no help with the missing connector side of things, but I'll share a solder-splice method with you that may help you add the correct light connector to the harness, and still have it fit in the wire loom when you reinstall it. I have a pair of alligator clips, connected to each other with about a 4" piece of coat hanger. The hanger is bent in a U so the clips point up, while the hanger is flat on the work bench. I have a spot on the bench that's got 2 screw holes in it to hold it in place with screws, or I can just let it dangle from the harness I'm working on. I strip the 2 wires I'm working with, feed one into one clip so its end is in between, slide some heat shrink tubing down the other end and clip it in so the stripped ends are overlapping. No twist, no holding hot wires with your hands...just heat and solder while the fixture holds 'em in place. Slide the heat shrink down, shrink it in place, and presto! A stretched wire. I'll get pics if that's as confusing to read as I think it is. IIRC, the stock taillight connector is a pair of spade connectors, loose, that go to either side of the light socket. Male on the light, female on the harness. Easy splice. If you want, I can also check the garage - I keep all sorts of stuff when I part cars, and I probably have the exact wire colors you need if you want that stock look. Just let me know what they are. I want to say they're gonna be orange/white stripe, and a black? | ||
| Brinnutz |
Joe, That's where it's messed up. The diagram from the FSM shows the taillamp connector as wires, but in reality it's a plug on the 2002's. So it's not like older models in that regard. Oh well... One day this bike will get put back together, I hope. | ||
| Ratbuell |
Simple solution (in my simple mind, anyway)? Buy an earlier taillight assembly with spade connectors. Make life easier for yourself in the future  FWIW, my 98 S1W has the spade hookups if you need an application. I think (but I'll doublecheck tomorrow) the taillight assembly is only about $35. | ||
| Brinnutz |
Well, now I don't know if I should get this used one: http://cgi.ebay.com/ebaymotors/Buell-Cyclone-M2-12 00-MAIN-WIRE-WIRING-HARNESS_W0QQcmdZViewItemQQ_trk parmsZ66Q3a3Q7c65Q3a10Q7c39Q3a1Q7c240Q3a1318QQ_trk sidZp3286Q2ec0Q2em14QQhashZitem130284525967QQitemZ 130284525967QQptZMotorcyclesQ5fPartsQ5fAccessories or the new one with 20% off for $170. Going to take awhile to save up for that. Rat, I would, but I'm trying to put everything back to stockish, or keep it as returnable to stock as possible. =) | ||
| Brinnutz |
Well now I am really screwed. The prices just got jacked up $150 and the harness is now $326!!!!!!!!!!!! I just got enough money to buy it when it was just last week listed at $173.60. I'm so frustrated right now....I just dropped $700 on it. I think it's time to sell it. This is absurd. Full time school, part time work and once a month navy, I save a while for that parts list. Damn, talk about hitting a brick wall. /vent and rant | ||
| Brinnutz |
Ok, I slept on it and am not going to sell the bike, against the advice of everyone around me that says it's a money pit that never runs.... Anyways, I just received my first $585 order of parts, and now I'm waiting on the $110 order from the dealer. I found a possible used wiring harness, so I guess that's the router I'm going to have to take. Here's to hoping it's in decent shape, and the right revision. | ||
| Damnut |
Put it in a crate and ship it to me. I'll take care of it. I have a nice Vespa that I need to get rid of, great gas mileage and very reliable. LMK  | ||
| Court |
Tell me about the Vespa . . . I'm may be looking to buy one. | ||
| Damnut |
2007 GT 200 ~1K miles on it. Bought it for the girlfriend but she never used it. Too tall for her, she's 5'1", so I got her a Blast. The Blast fits her perfectly and she loves it. Was going to keep it but I already have 2 Buells and an old 75 BMW R90/6 so no need to keep it in the stable. | ||
| Brinnutz |
No Jim, you can't have it. I'm going to finish this. I think I have found a GREAT solution, but that would require some internal help. Here's the idea: Obtain a "Taillight Harness" such as this: Measure approximately correct length of above harness, cut my M2 main harness there, or where it wouldn't interfere with anything. This is the part I can't figure out though, is that I'd somehow need to find the opposing end of the connector and pins for the wires found in the pic above. There's no part number or anything. I guess I could call customer service and ask. | ||
| Oldbiker |
Brinnutz.....seems to me the key word at this point is "stockish". Piece it back together with crimp on knife connectors. Steve | ||
| Brinnutz |
LOL, guess I shouldn't have used that word.  |
