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General Category >> Rubber Side Down! >> Lengthening the electrical wires to the handlebars
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Message started by 1st2know on 06/06/14 at 21:32:16

Title: Lengthening the electrical wires to the handlebars
Post by 1st2know on 06/06/14 at 21:32:16

So, I bought an S40 this year, and it runs perfectly, but I don't like the drag bars(stupid 21st century technology!) So, I want to "upgrade" it back to the Savage buckhorns.

I have the handlebar, mount, brake line, throttle, and clutch cable to do the job, that just leaves the electrical.

I calculate the wires need to be about 6 inches longer to fit the buckhorns.

How do I go about lengthening the wires? Should I solder in 6 inches wire for each circuit and then shrinkwrap them?

Title: Re: Lengthening the electrical wires to the handle
Post by justin_o_guy2 on 06/06/14 at 21:42:17

Yes, but dont cut the harness off straight across.. You dont want all those connections happening in the same place. It will put a lump in the harness,,
When connecting wire ends, dont twist them together by holding the insulation & cranking on the bare ends & soldering that, then slipping shrink on it,, Slip heat shrink on one end, line it up, cross the bare wire ends about 1/2 way, spin one one way & spin the other the other way & wind them around each other lengthwise,,solder, slip the shrink up, shrink it,, Makes for a much slimmer connection,

Title: Re: Lengthening the electrical wires to the handle
Post by Gary on 06/07/14 at 06:47:24

It is called a western union splice (google)
Gary

Title: Re: Lengthening the electrical wires to the handle
Post by 1st2know on 06/07/14 at 18:00:35

The spacing the joints apart is a good idea. I think I'll use hollow solder wick to hold the ends together and just dab some solder on to that to make a smoother joint.

Thanks!

Title: Re: Lengthening the electrical wires to the handle
Post by justin_o_guy2 on 06/07/14 at 21:54:06

I had no idea it had a name.. JUst time doin these things,, A guy makes a coupla messes & starts thinking about how to not do that,