Suzuki 800 Intruder Club & Forum
Welcome to suzuki800 Intruder forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, VZ800, VS800, C50, M50, Intruder / Boulevard / Marauder.

You will need to register before all the area's become visible, before doing so please enter & read the first thread in the Introductory area

It will only take a minute to register & it would be great to have you on board
This is a free to access and use site.
Suzuki 800 Intruder Club & Forum
Would you like to react to this message? Create an account in a few clicks or log in to continue.

Suzuki 800 Intruder Club & Forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
 
HomeRegisterLog in

 

 Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800

Go down 
AuthorMessage
Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
Mr Intruder


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeSun Aug 26, 2012 6:50 pm

I started the install for the extended cables that are required for the install of my ape hangers. First of all I cut in to the original sheath that surrounds and protects the wires, so that I could see the colour arrangement of the wires before doing the initial cut. I have read that a lot of people stagger the cut of the wires when doing this kind of cut and extend on wires so that they do not get a big bulge in the wires. However as I am not using any electrical connectors, there will be no bulbous area at either end of the install.

I cut the lengths of wire for this install at 10" lengths, in total there are 15 stock wires plus whatever else you may have installed on your bars. When both the original and extra cable has be de sheathed, twisted together and soldered, this will give me the additional 9" over stock that is required for my particular bars.

Tools & sundries used
8-amp wire (as this is what I had to hand)
Wire stripper
Soldering iron
Solder
2.5mm heat shrink (used to wrap soldered wires)
10mm heat shrink (used to re sheath the loom on the right)
13mm heat shrink (used to re sheath the loom on the left)
Heat gun or cigarette lighter, to shrink the heat shrink

On the left side the standard stock wires are as follows
(10 wires)
2 x Black/Yellow (be careful to mark one of these either side of the cut, to avoid mixing them)
1 x Black/White
1 x Black/Blue
1 x Black
1 x White
1 x Blue
1 x Green
1 x Yellow
1 x Yellow/White

On the right side the standard stock wires are as follows (5 wires)
1 x Black/Red
1 x Black/Blue
1 x Black/Orange
1 x Yellow/Green
1 x Orange/White


Here you can see the pre cut stock wires from the right side.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 IMG_0768

Here is the first end of the first wire that I have soldered. If you are not someone that usually solders wires, you will be shocked at how little solder is required to get a join that is nigh on impossible to brake.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 IMG_0769

Here you can see that I have now heat shrinked the wire, to insulate it.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 IMG_0770

As you can now see, I have now joined, soldered and heat shrinked all of the wires at one end.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 IMG_0772


When doing the final soldering that completes the loom, I found that it was necessary to have something to lean on. This was due the weight of the existing wires and the fact that everything seemed to want to go in any direction apart from where I wanted it. I found by sheer luck that my wooden bike jack was exactly the height that was needed when stood on its end.
It is also really important to remember to slide some heat shrink on to one of the wires before soldering, so as to avoid having to separate them again and then resolder. I forgot twice, so I speak from experience.
Also before starting to solder this section you will need slide on the larger heat shrink that will form the outer sheath to the completed loom. If you forget to do this you will need to tape the wires.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 IMG_0775

And here we are with the finished loom.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 IMG_0776


This would at first seem like a daunting task but is a really simple and cheap way to extend your wires in preparation for ape hangers. The whole install of extending the wires for both sides took me about 4 hours from start to finish & thats with lots of interruptions as our house is like Piccadilly Circus at rush hour.


Last edited by Mr Intruder on Mon Aug 27, 2012 5:44 pm; edited 2 times in total
Back to top Go down
captain crash
Mentally Deficient lunatic ..... & ..... Site Moderator
captain crash


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 4:58 pm

Another excellent write up Dave, you reall are a one man modification machine Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 881924
Back to top Go down
Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
Mr Intruder


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 5:02 pm

Cheers Crash Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 3498837457
To be honest, if I didn't do these things myself they wouldn't get done. No way could I ever get even a quarter of what I do myself done, if I was paying someone else to do it for me.
Back to top Go down
Bluesman
Very Valued VIP Member
Bluesman


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 6:12 pm

Dave I am full of admiration for the way you work. I found no problem with the technical side of things but deciding what needed doing and finally having the balls to go ahead....ah that's another matter. I'm sure this won't be the last apehanger install on the site as you are making it look very doable. I just watched the Moto GP on iPlayer but this write up was more compelling (did I just say that?!)

Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 2170595768
Back to top Go down
Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
Mr Intruder


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 6:19 pm

Kind words John Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 3005623951
I hope to get the apes on over the next week or two if all goes to plan. I have done the clutch cable & now finished the electrics, so I need to pull my finger out and get the extended brake hose fitted & make up the throttle cables.
All things come to he who waits.
Back to top Go down
Bluesman
Very Valued VIP Member
Bluesman


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 6:26 pm

Oh forgot to ask - did everything work again when you switched on?
Back to top Go down
Mr Intruder
Suzuki800.com Founder ... & ... Senior Administrator
Mr Intruder


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 6:31 pm

Bluesman wrote:
Oh forgot to ask - did everything work again when you switched on?
Like a dream John, I was very meticulous at ensuring the right ends got put together. It would be so easy to put the wrong ends together when all the wire used is one colour though.
It would be a real pisser if you did all that work and you pressed the horn and the indicators came on Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 2740622253
Back to top Go down
alfie92
Very Valued VIP Member
alfie92


Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeMon Aug 27, 2012 9:36 pm

Good write up as usual Dave,looking good m8.
Back to top Go down
Sponsored content




Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Empty
PostSubject: Re: Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800   Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitime

Back to top Go down
 
Extended Electrical Loom Install For 14" Ape Hanger Bars on 2010 C800
Back to top 
Page 1 of 1
 Similar topics
-
» HID Conversion Kit Install Instructions
» Rhino 660 Speedo Install
» Ranger Clutch Kit install, RZR mostly the same
» Hunterworks stage I cam install test results.....
» Snorkel Install

Permissions in this forum:You cannot reply to topics in this forum
Suzuki 800 Intruder Club & Forum :: The Garage :: General Electrical Modifications, Help & Information.-
Jump to:  
Slide Show
A random selection of suzuki800.com member bikes.
Latest topics
» Slammed Volusia - 2" lowering kit - video
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby buzz5019 Thu Jul 09, 2020 9:37 pm

» VX800 exhaust advice
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby oldmick Thu Jul 09, 2020 8:05 pm

» Hi everyone
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby stingray Thu Jul 09, 2020 1:57 pm

» Suzuki C50/C800 valve adjustment procedure tips
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby EazyDuz Wed Jul 08, 2020 10:42 pm

» Cooling fan troubles
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Dushmth88 Wed Jul 08, 2020 7:27 pm

» Debaffled and looking for end caps
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby rehanpk Tue Jul 07, 2020 7:34 pm

» Tail light fuse blowing
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby hmac Tue Jul 07, 2020 1:57 pm

» * Suzuki C800, De-badge *
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Badger Fri Jul 03, 2020 5:19 pm

» Single red and blue wire help
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby ardie Tue Jun 30, 2020 5:55 pm

» New old guy
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby ardie Tue Jun 30, 2020 5:46 pm

» Hi Suzuki drivers
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby ardie Tue Jun 23, 2020 1:01 am

» Hello
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Badger Sun Jun 21, 2020 10:51 am

» Lft side swing arm cover - decoration or functional?
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Badger Sat Jun 20, 2020 12:48 pm

» Advice on carrier needed.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Holstein Thu Jun 18, 2020 6:50 pm

» Helllo
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Badger Thu Jun 18, 2020 10:52 am

» Bad vibrations
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Badger Tue Jun 16, 2020 1:31 pm

» 50/50 vinegar flush.
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Badger Mon Jun 15, 2020 2:41 pm

» Vz800 speedometer
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Mpiercy94 Sun Jun 14, 2020 11:43 am

» Hello
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby Pygsli Sat Jun 13, 2020 7:01 pm

» Front wheel gap?
Extended Electrical Loom  Install For 14" Ape Hanger Bars on 2010 C800 Icon_minitimeby ardie Sat Jun 13, 2020 6:34 pm

Log in
Username:
Password:
Log in automatically: 
:: I forgot my password