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[Twolanerider]

With the sensor harnesses installed and secured the remaining loose connections are next to be done.  Three of these connections are made with no further routing and are done under the right side cover.  Two connections are made with wires that route part way or fully across the bike.

The written instructions supplied with the kit could be interpreted such that one might route these two wires under the seat and over the frame tubes.  That seems an unnecessary risk.  Different saddles have contact bumpers in different places.  When it is this easy to route the wires across while also under the frame tubes so they can never be pinched from above there’s no reason not to.

Feed the wires that are system power and system ground in to the battery cavity.  You will pick them up on the other side of the frame tube.  The power wire will feed all the way across.  The ground wire will turn forward in front of the battery and ground at one of the grounding lugs in the well in front of the battery.

[Twolanerider]

Ground wire shown here already attached.  Disregard the round aluminum device to the left of the ground point.  It is the compressor for the air horn installed on this bike.  It also lives in the well in front of the battery and had to be moved to access the ground lug to make this connection.

[Twolanerider]

Power wire shown here after being fished through the front of the battery compartment.  There are several extra electrical accessory circuits on this bike whose harnesses and connections make this area crowded.  Your retrieval will be simpler than what is shown here.

[Twolanerider]

Revolution Performance suggests making the power connection using one of the provided wire taps shown earlier and making that connection to the solid blue headlight wire coming out of the bottom of the fuse box.  This is an easily accessible wire.  Using the wire tap makes for a simple connection.  This is their preferred power source.

If you choose to get power from some other location please note that the source must be switched (comes on with the ignition switch) but must not be hot when the ignition switch is in the “Accessory” position.  Revolution Performance warns that energizing the interpreter module for extended periods without the engine running could damage the module.  If powered from an accessory circuit you might do this playing the bike’s radio on a hotel parking lot some evening

[Twolanerider]

Three connections yet to make.  Disassembling the large ECM connector was the most daunting part of this install to some that have been interested.  The EMS kit supplies the new ECM wires with terminals already installed.  So no need for any special crimping tool.  In fact there’s not a single wire crimp for the entire installation.

Opening up the ECM connector isn’t difficult.  Locate the wire tie that holds the harness at the connector and cut it.

[Twolanerider]

The clear plastic cap that protects and aligns the wire terminals is removed by pushing in on locking tabs located at each end of the cover.  Once the tabs are released the cover pops off easily.

[Twolanerider]

Once the cover is off you can see the existing terminals.  Just like the two new ones you’ll be adding.  You can also see that several pin locations are still unused.  On this 2005 bike’s ECM Harley already had AFR monitoring well along and close to production.  The 05 ECM has significantly more onboard memory than do the 2001-2004 Delphi ECMs to handle the processing task.  The basic internal code to handle the task is there already as well.  2006 bikes got what 2005 bikes were preparing for.

[Twolanerider]

To finish opening the housing find the small clips that hold the two halves together.  Pry them open with a small screwdriver.

[Twolanerider]

Once the tabs are released the housing spreads open to allow access to install the two new wires.  These wires each carry data from an oxygen sensor.

[Twolanerider]

Another question that’s been common was how to make sure the additions to the ECM connector are made in the right position.  Revolution Performance’s instructions specify a numbered location in the ECM connector for each wire.  Once the clam shell is open the numeric locations are easily identified.

[Twolanerider]

There will be plugs in each unused hole.  Locate the two that need to be removed.  They can be pulled with a small needle nose plier.

[Twolanerider]

With the clamshell open and the plugs removed add the two new wires to the ECM connector.  Slice open the sheath making an opening a couple inches long.  Then push the new wires through this opening and out the end of the sheath next to the ECM connector.  This way when the clam shell is closed and a wire tie reattached any potential rub is entirely against a still in tact protective sheath and not potentially against any uncovered wires.

[Twolanerider]

Be sure to push the new terminal inside the ECM socket until it snaps in place.  If inserted only far enough to cover the wire insulation it is not fully installed (as shown in this picture).  You should push the wire through far enough that the new terminal is actually slightly “taller” than the existing terminals.  Then when pulled back it is locked in place.

Once the two insertions are complete you can snap the clamshell closed, reattach a wire tie at the clamshell’s collar and snap the clear cover back on.  What for many might be the “scary part” is now done.

[Twolanerider]

With the new connections to the ECM completed there is one connection yet to be made.  A single unterminated black wire that must connect to another wire inside the bike’s ECM harness. 

Take the black wire in hand and see how far up the harness sheath it reaches.  Somewhere comfortably short of that slice an opening in the sheath about three inches long.  In the harness find a black wire with a white tracer.  It is seen here laying on top of the small screw driver after it has been fished out of the harness.  This wire is the final connection to complete the harness installation.

[Twolanerider]

Once the black/white wire is located use one of the supplied wire taps and make the connection with the new wire from the EMS kit.  Once done close the harness sheath up as well as you can and the harness installation is complete.  The “hard part” is now completely done.  You are now waiting impatiently for the ECM to get back from its trip to Revolution Performance.