Bagstr 287 Posted April 4, 2020 https://www.bikeexif.com/motorcycle-wiring My son sent a Link from this E-Magazine. Interesting topics. This one is on How your motorcycle electrics works. Who Knew? Share this post Link to post Share on other sites
Uncle Champ 116 Posted April 4, 2020 Wow, all that info in one place. I remember when I was changing my 450x to street legal I found an older Honda that was on a front bumper rack of a pickup in a wrecking yard. The bike was the first vehicle to the wreck. Anyway I painstakingly took the bike apart labeling the wires and making a hardcopy of what wires went where. It turned out that actually it is all pretty simple when all laid out on paper. There were things like LED lights don't blink right with regular flashers etc. But even things like horn wiring is fairly strange the first time around. Don't be afraid, if I can do it so can you. Cheers, Share this post Link to post Share on other sites
Bagstr 287 Posted April 5, 2020 " Just remember to keep the wires secure and away from any sharp edges or heat sources. Broken or melted wires are the most common source of electrical failure I see. " I will add; Any non-factory crimp connector should looked at with suspicion as the wire can easily loosen or pull out of the terminal. Share this post Link to post Share on other sites
Covered in Dust 162 Posted April 5, 2020 I bought these and put a few in my kit for emergency repairs on the trail. 120 PCS Solder Seal Butt Connectors, Automotive Marine Waterproof Solder Wire Connectors, Insulated Electrical Butt Splices for Boat Truck Trailer https://www.amazon.com/dp/B07B2WS9HQ/ref=cm_sw_r_cp_tai_7FGIEbP1N7Q90 CiD Share this post Link to post Share on other sites
PbdBlue 46 Posted April 5, 2020 4 hours ago, Bagstr said: " Just remember to keep the wires secure and away from any sharp edges or heat sources. Broken or melted wires are the most common source of electrical failure I see. " I will add; Any non-factory crimp connector should looked at with suspicion as the wire can easily loosen or pull out of the terminal. Aftermarket crimps though unsightly are pretty robust if done properly with the correct tool. This is the proper tool: This is NOT: That said I still prefer to solder and heat shrink. You do need to be aware though that soldering embrittles the wire so proper strain relief is important. 1 Share this post Link to post Share on other sites
TexasDualler 32 Posted April 5, 2020 I'll throw in that when installing "factory" connectors you'll need the proper crimping tool to place the pins on the ends of wires. I have one of these in my tool box from when I put a KTM style Molex connector on a powered GPS mount: Share this post Link to post Share on other sites
Bagstr 287 Posted April 5, 2020 https://www.homedepot.com/p/Channellock-4-5-in-Tongue-and-Groove-Straight-Jaw-Pliers-424/306089834 All These Tools are fine for the garage; but for the trail Chris' cold solder or a crimp is all you can hope for. That said, I would be looking for a wire rubbing the insulation off out on the trail. At that point some 3M 33 tape and a new fuse will get you going. But Really, We are in the maintenance mode until we get a vaccine. Spending my time with moto maint and fine tuning until That Happy Day. Thanks for the input Gents Share this post Link to post Share on other sites
Covered in Dust 162 Posted April 6, 2020 I made a few test with the connectors. They are pretty strong and you can melt the solder and the heat shrink with the heat from a match or lighter. Share this post Link to post Share on other sites
PbdBlue 46 Posted April 6, 2020 Here's an interesting factoid regarding wire choice. Just ran across this so have not verifed any of it but it looks legit. https://www.lapptannehill.com/what-are-the-differences-between-the-types-of-primary-automotive-wires?utm_medium=post&utm_source=facebook&utm_campaign=automotive&fbclid=IwAR3S6PBaa4LyJxSOgNseaputgN7gVW948rE_I_pG215nJ46LpDlROwbn-ZI 1 Share this post Link to post Share on other sites
Bagstr 287 Posted April 6, 2020 Edited 125 C is equal to 257 F https://www.napaonline.com/en/p/BEL733302?partTypeName=Primary+Wire&keywordInput=cross+link+automotive+wire Randy, Looks like NAPA sells the stuff. This would be better than construction THHN high temp wire because the THHN has a tough clear layer that cracks and breaks down in high heat and friction. Plus it is only rated at 105 C. Good Find, Thanks Dave Share this post Link to post Share on other sites
Mr.JAJA 380 Posted April 6, 2020 One more, alow slag to the wire, but tightened to the frame. Share this post Link to post Share on other sites
Ptkatoomer 114 Posted April 6, 2020 37 minutes ago, Mr.JAJA said: One more, alow slag to the wire, but tightened to the frame. Do you mean "slack " , so there's no tension on the wires? Share this post Link to post Share on other sites
Mr.JAJA 380 Posted April 6, 2020 yes, that what I meant. And I dont worry about electric. Share this post Link to post Share on other sites
Zubb 1061 Posted April 6, 2020 That article makes me want to buy an old bike and wire it up! You know it's well written because even I can understand it. Share this post Link to post Share on other sites