How to Separate Top Box Bottom Half Inner/Outer

[AZBob]

So I'm well into my third brake light and interior light in the top box project. The only real thing holding me back right now is the top box itself. Does anybody know how to separate the inner and outer halves of the bottom half of the top box? (the top part is cake, obviously)

I have removed every screw I can see and it still won't come apart. I can drive a plastic wedge between the halves and nothing is holding the sides from the top as far as I can see, it seems to be being held from the bottom, perhaps by glue, perhaps mechanically by something I haven't disassembled yet. I took the cover off the plug-in harness mechanism and there's nothing under there I can see that would be holding it together. I haven't taken that assembly out, however, as there is a metal bar that connects the handle to the slider that moves the connector toward and away from the connector on the sliding carriage when it's on the bike. I am a little afraid of breaking the handle/lock mechanism prying things apart.

[ShaunDW]

I would also be interested to learn the correct procedure to do this for fitting an additional brake light. I have been told by my dealer that it is not something that they like to do, as it often ends in a breakage.
Additionally has anyone looked into the plug-in harness with regard to adding wires to it? There appears to be capacity for two extra pins within the plug/socket that is used, but is it possible to obtain the correct pins?

[AZBob]

Originally Posted by ShaunDW

I would also be interested to learn the correct procedure to do this for fitting an additional brake light. I have been told by my dealer that it is not something that they like to do, as it often ends in a breakage.
Additionally has anyone looked into the plug-in harness with regard to adding wires to it? There appears to be capacity for two extra pins within the plug/socket that is used, but is it possible to obtain the correct pins?

Regarding extra pins, yes, you can (although expensive). You just need to purchase another sliding carriage wiring harness and a top box wiring harness, which will give you two more male and female pins. Each harness is about $35, which is ridiculous for essentially four wires. It's about $5 worth of parts. I will be running unswitched power and brake light power on those two wires to power the brake/running light and interior light (there's already switched power and ground). Fortuitously, the box has space molded into the interior part specifically where one would want to place a running/brake light and interior light.

I am going to try to feed some fishing line between the halves and see if I can draw it between them to see if it's just glue holding the halves together. They must come apart as there's no reason to sell the top box wiring harness as a separate part if you can't because you can't service the harness otherwise (without separating the halves, there's no way to get to the part of the wiring that hooks to the 12v socket directly).

[AZBob]

So, I emailed Triumph on how to separate the two halves, but in a bit of inspiration, I think I realized I don't need to actually do that. In looking at the bottom, there is an access panel with six screws that covers the sliding electrical connector that mates to the static connector on the sliding carriage. I believe I can just add the pins I need (you can access the connector with that cover off), tap the two wires already there, drill a small hole in the back of where all of this stuff is, and fish the wires up between the the inner and outer case to get to the top of the case, which is what I would have done anyway. Very excited now. :-) Of course, I will post a how-to when I get everything working (I've been taking pictures along the way).

[ShaunDW]

Sounds promising.

Regarding the OEM harness, I have found a part number for the sliding carriage harness, but not the top box harness. My dealer was also unable to help with this saying that the top box is available complete with no constituent parts listed (apart from the cover). I'm not saying that I will go that way, but I would like to know what is available, so if anyone has a part number for the top box harness I would appreciate it.

AZBob - You currently plan to add the pins you need to the existing connector. Have you identified the specific pin type and a source from where to obtain them?

[AZBob]

Originally Posted by ShaunDW

Sounds promising.

Regarding the OEM harness, I have found a part number for the sliding carriage harness, but not the top box harness. My dealer was also unable to help with this saying that the top box is available complete with no constituent parts listed (apart from the cover). I'm not saying that I will go that way, but I would like to know what is available, so if anyone has a part number for the top box harness I would appreciate it.

AZBob - You currently plan to add the pins you need to the existing connector. Have you identified the specific pin type and a source from where to obtain them?

The top box harness is part #4 in this diagram: http://www.bikebandit.com/oem-parts/2014-triumph-trophy-se/o/m155995#sch807452

I haven't found the pins anywhere (nor have I looked very hard)... the pins are probably < $.01 each or so, so I probably should have done that, but it's hard to figure out what you're seeing from line drawings. I purchased the two wiring harnesses for their associated exorbitant prices.

[jesse64]

That connector looks an awful lot like what's called a Weatherpak Terminal.
http://www.whiteproducts.com/terminals-seals.shtml

I had thought about adding lights to the top box too but I don'tr really have it on that much.  I'd love to see it when you're done.  I'm in North Scottsdale.

[Phil]

If you've taken out all the screws then the outer shell of the top box should just lift off.  I took mine off the other week to install a luggage rack on top.  it was a simple job although I did make it more complicated by undoing the screws that held the release and locking system which I need not have done.

By the way, the luggage rack I put on is a chrome Gold Wing piece and was very easy to fit.  PHotos shortly. 

So far no problem with the extra weight and I will only be putting waterproof over gear on the rack.   However, with the rack in place I think I have to be careful when opening the top box as I am not confident in the nylon restraining straps on each side of the lid.

Freeway Phil