 Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Folks:
I'm finally getting around to running the wires inside my new Heritage bars. Question on the throttle side:
- The two black brake light wires, they are both the same color wire. Does it matter which is which?
- Same question for the two starter wire buttons, does it matter which goes to which in the connector?
I need to pick up some wire cover from Pep Boys tomorrow, I'm ready to do that end of the soldering.
Al
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 9,223
Big Bore
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Big Bore
Joined: Jan 2005
Posts: 9,223 |
No it doesn't but I still labeled them before I cut and added longer unique colored wires to each.
"Never underestimate the power of human stupidity" - Robert Heinlein
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Quote:
No it doesn't but I still labeled them before I cut and added longer unique colored wires to each.
Great, thanks for confirming. I did the same, except for the brake wires, ran a one color to both, but different from the rest of the bundle.
Al
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
You guys would get a headache with mine, all green wires  I just labeled them on some masking tape like "RB" for "red with blue stripe", except I used the letter coding that the manual uses. Worked out well.
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 9,223
Big Bore
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Big Bore
Joined: Jan 2005
Posts: 9,223 |
Quote:
all green wires
Oh my... 
"Never underestimate the power of human stupidity" - Robert Heinlein
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 2,362
Oil Expert
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Oil Expert
Joined: Jan 2005
Posts: 2,362 |
Quote:
You guys would get a headache with mine, all green wires
I just labeled them on some masking tape like "RB" for "red with blue stripe", except I used the letter coding that the manual uses. Worked out well.
Y'know Benny, there ARE easier ways to make extra work for yourself.
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Re: Wires in Bars Question
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Joined: Feb 2007
Posts: 23,217 Likes: 61
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,217 Likes: 61 |
YES!! The darker black one is pos. and lighter one is neg!!!
LOL Kidding.
Mine are all red. LOL
My chopper the whole wireing harness is red! LOL
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
And I never got any wires crossed!! The second time I did it, it wouldn't start. No click, no nothin. Turns out one of the wires had come off the back of the starter button!! Yikes. A few of the guys (Rob especially) helped me re-solder it back on, which turned out to be easy, and I was on my way.
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: Mar 2006
Posts: 1,540
Learned Hand
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Learned Hand
Joined: Mar 2006
Posts: 1,540 |
1 quick question what gauge wire is used?
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
I think I used thocker than necesary.... Someone mentioned it earlier, I want to say 18.
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: Feb 2007
Posts: 23,217 Likes: 61
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,217 Likes: 61 |
I went thick too. I believe I used 16 ga. Just cause when I got the bug up my butt to do it thats the thinest I had a spool of.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
I think I did too. Come to think of it, all my wires are blue now
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: May 2006
Posts: 3,971
Loquacious
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Loquacious
Joined: May 2006
Posts: 3,971 |
If you ride fast enough, you can skip half those pesky signal and brake light wires
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 Re: Wires in Bars Question
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Joined: Feb 2007
Posts: 23,217 Likes: 61
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,217 Likes: 61 |
I didn't know there was break and turn signal lights. 
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: Wires in Bars Question
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Joined: Sep 2006
Posts: 176
Adjunct
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Adjunct
Joined: Sep 2006
Posts: 176 |
Quote:
1 quick question what gauge wire is used?
Use 18 gauge. Most of the stock wires are 18, a few are only 20, but 18 is ideal and the smaller the gauge the better for clearance etc.
'06 Speedmaster, DBA Performance Pipes, re-jetted, needles, Snorkel / AI removed, shiny bits......
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
I agree with the 18 gauge wire. I had a lot of 16 gauge and it too thick to work.
Also, the Dremel (or other rotary tool) is your friend. Does a great job on smoothing the holes. I used a small cutting tool to join the two holes in the center as well.
Al
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Re: Wires in Bars Question
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Joined: May 2006
Posts: 3,971
Loquacious
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Loquacious
Joined: May 2006
Posts: 3,971 |
A minor snag I hit - the wire batch they used on my headlight dimmer switch and clutch switch was black with a double red trace, and red with a double black trace. The traces were nearly as wide as the wire colors. The two wire's color schemes appeared to be identical to my ancient presbyopic (tri-focal) eyes. A lot of folks use one large hole at the bar center for the wires. Not to rock the boat, or to suggest otherwise -- but I drilled two 1/2" holes for the wires near the bar's center, as my deal is to have a third wire dead center for the bar mounted tach. An alternative to stainless loom is plastic chrome loom. http://cableorganizer.com/automotive/http://cableorganizer.com/convoshield/I'm happy with the plastic stuff, but the stainless would certainly be a notch or two better. Just a thought.
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Re: Wires in Bars Question
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Joined: Feb 2007
Posts: 23,217 Likes: 61
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,217 Likes: 61 |
ssjones did the same I did. Small fiber reenforced cutting wheel on the dremel worked great to join the center holes. Small grinding stone to smooth the burrs. Be aware that the stones on the dremel ate away pretty fast but did a very good job in short order.
I used 16Ga while I don't reccomend it , it did work.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: Wires in Bars Question
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Joined: Sep 2006
Posts: 176
Adjunct
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Adjunct
Joined: Sep 2006
Posts: 176 |
Quote:
A lot of folks use one large hole at the bar center for the wires. Not to rock the boat, or to suggest otherwise -- but I drilled two 1/2" holes for the wires near the bar's center, as my deal is to have a third wire dead center for the bar mounted tach.
An alternative to stainless loom is plastic chrome loom.
I used two holes and found some real nice stainless material to use to house the wiries, both from the bars to the lamp and from the signals. Take a look.
'06 Speedmaster, DBA Performance Pipes, re-jetted, needles, Snorkel / AI removed, shiny bits......
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
First time I did it I joined the holes. Last time, I kept them separate. I think it's cleaner, but definitely a personal choice. I may go back and touch up the holes and then try to coat the bare metal with something so it doesnt rust. 
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Well I'm done and everything works properly. I have to say, this was not a small job. I've been contemplating this job for about two years, but since adding the taller bars it became a necessity. The taller bars look ten times better without the wire bundle hanging alongside. Hopefully my solder joints will hold up. 
Al
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
Nice!! Amazing how much cleaner it looks, right? Good job!
Not a small job, but not really hard, right?
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Quote:
Nice!! Amazing how much cleaner it looks, right? Good job!
Not a small job, but not really hard, right?
I probably spent about five hours doing the work on two evenings. Awkward would be a good word. My back was killing me for bending over the front end for so long. I probably should have drilled a larger hold on the clutch side. I used a piece of fly fishing leader to pull all the wires through. Ran a piece through connected to a spool. I kept repulling that length, but if it broke, I wouldn't lose the lead.
Al
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 12,877
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 12,877 |
Good idea. I wrapped the bundle in some tape and pushed By the last time I did it, after I drilled the bars, I just left them in my bench vice and did all the wiring and soldering on my bench. Then installed the bars and connected the connectors in the headlight. The only thing about that is you need to watch your brake resevoir, consider bleeding it after. A fair trade for not bending over!
Benny
Black & Silver '02
Too many mods to list
Not enough miles ridden
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Quote:
Good idea. I wrapped the bundle in some tape and pushed
By the last time I did it, after I drilled the bars, I just left them in my bench vice and did all the wiring and soldering on my bench. Then installed the bars and connected the connectors in the headlight. The only thing about that is you need to watch your brake resevoir, consider bleeding it after. A fair trade for not bending over!
Yep, that would be a vertebrea saver!
Al
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Re: Wires in Bars Question
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Joined: Feb 2007
Posts: 23,217 Likes: 61
Fe Butt
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Fe Butt
Joined: Feb 2007
Posts: 23,217 Likes: 61 |
I took the bars off and did it watching TV in my living room took about an hr all together. Maybe another hr dissassembly and reassembly time.
I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Quote:
I took the bars off and did it watching TV in my living room took about an hr all together. Maybe another hr dissassembly and reassembly time.
NOW the tips coming flying in!
Al
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Re: Wires in Bars Question
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Joined: Sep 2006
Posts: 176
Adjunct
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Adjunct
Joined: Sep 2006
Posts: 176 |
Looks great man - worth it right ?
'06 Speedmaster, DBA Performance Pipes, re-jetted, needles, Snorkel / AI removed, shiny bits......
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Re: Wires in Bars Question
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Joined: Jan 2005
Posts: 5,537
Check Pants
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OP
Check Pants
Joined: Jan 2005
Posts: 5,537 |
Quote:
Looks great man - worth it right ?
Definitely, even with a windscreen it is a noticable improvement.
Al
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