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-handle bar wire extension-07 fattie

Discussion in 'Motorcycle Tech Talk' started by fred815, Mar 3, 2009.

  1. fred815

    fred815 New Member

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    whats the best way to extend my handle bar wires? Other than cut splice solder umpteen times??? seems I could get a hold of some molex connectors, pins and wire and make up my own plug and play extensions?? but where
    fred815, Mar 3, 2009
    #1
  3. ironhorse

    ironhorse Active Member

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    if your wanting plugs for your scoot the only molex I know of and played with are for p.c., electronic/ type of application not so much for heavy outdoor enviroments, but not saying there isn't an application out there, the connectors that I use because of thier easy repair, and weather tight connections, low resistance, and durability are the deutsch connectors
    they get used on every thing frome weed eaters to the aerospace, and are avalible just about everywhere
    ironhorse, Mar 3, 2009
    #2
  4. chucktx

    chucktx Moderator Staff Member

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    what ever you use, use the same grease you use on the sparkplugs....anabolic..(sp).......and heatshrink.....
    chucktx, Mar 3, 2009
    #3
  5. hotroadking

    hotroadking Super Moderator Staff Member

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    Harbor Freight had a sale going on Midex Wire Stretchers $14.95 each...
    hotroadking, Mar 4, 2009
    #4
  6. fred815

    fred815 New Member

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    molex

    Oops thought for sure they were molex connectors for the handle bars. Gonna take a closer look for sure.:gah:
    fred815, Mar 4, 2009
    #5
  7. 00 wildglide

    00 wildglide New Member

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    Check the Dennis Kirk catalog.I saw a page that showed an assortment of connectors available.I'm sure other companies + local dealers will have what you need.Splicing is o.k. as long as you solder,heat-shrink,& use the proper wattage soldering iron.
    I've seen many wire repair jobs that looked worse than the original problem.
    Hope this helps,00 wildglide:cool:
    00 wildglide, Mar 4, 2009
    #6
  8. hotroadking

    hotroadking Super Moderator Staff Member

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    HD might even have extenders with the correct connectors on each end.

    Thing is you have to get them inside the bars if you're doing an internal wire setup

    The way I've done in the past is to cut to length the applicable number of extensions out of a spool of black wire, correct gauge.

    then stagger your cuts on the existing wire harness so very few of the cuts when reassembled will be next to each other, this keeps the wire harness thinner when done. If you put all the cuts in one area you'lll have a bulge that will be hard to pull through.

    You leave the end piece on the wire, then butt joint the new section in, say you have the orange and white stripe wire, cut, then butt joint and soldier in the new piece, cover with heat shrink, that way the tip is the proper color so you know where it goes in the connector.

    The other thing you can do, is spend some moola but get a new set of HD Dyna switches with wires, and replace everything. Most bars unless you go over 16 up will work with dynas without any cutting. Dynas have the longer wires of all stock setups.
    hotroadking, Mar 5, 2009
    #7
  9. ironhorse

    ironhorse Active Member

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    if you cut to splice then the heat shrink/solder conectors I get from fastenal are the catsass, no crimp just heat , try um youll like um
    ironhorse, Mar 5, 2009
    #8
  10. chucktx

    chucktx Moderator Staff Member

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    i have not used them, but have heard good reports about them.....
    chucktx, Mar 5, 2009
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