Trail Tech DIY
Post Reply    Forum -> Not-So-Modern
Author Message
Addicted
P125X, P200E
Joined: 02 Apr 2011
Posts: 790
Location: Fresno, CA
Sun Apr 04, 2021 2:40 pm quote
I want to splice in several feet of wire on my Trail Tech CHT. Does anyone know what gauge those two wires are? Any reason I shouldn't do this?
Ossessionato
Joined: 26 Oct 2015
Posts: 2953

Sun Apr 04, 2021 2:50 pm quote
Re: Trail Tech DIY
Fatbear5 wrote:
I want to splice in several feet of wire on my Trail Tech CHT. Does anyone know what gauge those two wires are? Any reason I shouldn't do this?
You can also go the easy route and just buy an extenion from TT.
Hooked
PX 200
Joined: 25 May 2016
Posts: 264

Sun Apr 04, 2021 6:52 pm quote
Interested too, looking to do the same...

Looking at recreating the connectors because of the wiring through the handlebars.
bodgemaster
63 GL, 76 Super (x 2), 74 Primavera (x 2), 06 Fly 150
Joined: 26 Sep 2013
Posts: 5768
Location: So Cal
Sun Apr 04, 2021 7:48 pm quote
I used 22 gauge.
Ossessionato
2015 GTS300, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4599
Location: San Diego, CA
Sun Apr 04, 2021 7:54 pm quote
I too bought the extension. I like clean connectors and less solder joints to fail.
Ossessionato
Joined: 26 Oct 2015
Posts: 2953

Sun Apr 04, 2021 8:05 pm quote
108 wrote:
Interested too, looking to do the same...

Looking at recreating the connectors because of the wiring through the handlebars.
If you want to recreate the connectors, TT uses J.S.T. connectors. You will also need JST propriety crimper tool. So either use 22 gauge like SoCalGuy, or buy the extension. Either will work.
bodgemaster
63 GL, 76 Super (x 2), 74 Primavera (x 2), 06 Fly 150
Joined: 26 Sep 2013
Posts: 5768
Location: So Cal
Sun Apr 04, 2021 9:16 pm quote
IMO the extension is a waste of money. The connectors are too bulky ... they donít fit through the opening from the headset to the switches or through the grommet for the harness.

I ran a long splice of two 22g wires twisted together from the engine through the frame and up into the handlebars. I snipped both connectors off about 3Ē from the ends, and spliced them on to the new wire with solder & heat shrink. Itís a clean install and gauges work perfectly.

9F78A1EA-14D9-4E22-8E82-1A6861280E40.jpeg

Hooked
PX 200
Joined: 25 May 2016
Posts: 264

Mon Apr 05, 2021 2:47 am quote
SoCalGuy wrote:
IMO the extension is a waste of money. The connectors are too bulky ... they donít fit through the opening from the headset to the switches or through the grommet for the harness.

I ran a long splice of two 22g wires twisted together from the engine through the frame and up into the handlebars. I snipped both connectors off about 3Ē from the ends, and spliced them on to the new wire with solder & heat shrink. Itís a clean install and gauges work perfectly.
Good to know itís something other folks are doing... that was going to be my plan B...
Molto Verboso
2007 Stella 225
Joined: 02 Nov 2019
Posts: 1571
Location: Rochester, Minnesota
Mon Apr 05, 2021 2:52 am quote
108 wrote:
SoCalGuy wrote:
IMO the extension is a waste of money. The connectors are too bulky ... they donít fit through the opening from the headset to the switches or through the grommet for the harness.

I ran a long splice of two 22g wires twisted together from the engine through the frame and up into the handlebars. I snipped both connectors off about 3Ē from the ends, and spliced them on to the new wire with solder & heat shrink. Itís a clean install and gauges work perfectly.
Good to know itís something other folks are doing... that was going to be my plan B...
Use this as your plan A if you can solder.
Addicted
P125X, P200E
Joined: 02 Apr 2011
Posts: 790
Location: Fresno, CA
Mon Apr 05, 2021 9:07 am quote
Thanks Guys. I have 22 gauge wire so I'll go with that.
Ossessionato
2015 GTS300, 1974 Primavera, 04 Ninja 250
Joined: 04 Apr 2013
Posts: 4599
Location: San Diego, CA
Mon Apr 05, 2021 10:35 am quote
I think each bike model is different, the connectors fit everywhere on my P. On the smallie i actually just remembered that I stole the turn signal wires instead of an extension, so Iím in both camps .
Enthusiast
VBA
Joined: 12 Mar 2018
Posts: 94
Location: Texas
Tue Apr 06, 2021 8:47 am quote
SoCalGuy wrote:
IMO the extension is a waste of money. The connectors are too bulky ... they donít fit through the opening from the headset to the switches or through the grommet for the harness.
Agreed.

I found the connectors to be bulky as well to route the cable how I wanted it (snake it through the split in the VBA headset). I ended up taking apart the connector on one side of the TT extension. Then I was able to easily route it with just the 2 pins loose, then put the connector back on once the extension was in place. I don't know if I would do it this way next time.

I found the TT extension to be a tad short when routed the cable from headset to underneath tank. It was a PITA to re-assemble the connector in the tight confines of the bottom of the tank area. I would go bottom up next time for extension.

I would say the harness is a good quick solution, however if you already have 22 gauge wire and heat shrink tubing I would probably go that way.
Hooked
Stella 2T 150, Honda C70
Joined: 25 Sep 2019
Posts: 157
Location: Seattle
Tue Apr 06, 2021 10:06 am quote
I did this using thermostat wire. Its a solid core wire which makes it a little easier to push through the body and it solders up with the existing wires easily enough. Just keep the solid core wires in the body.

Hal
Molto Verboso
2007 Stella 225
Joined: 02 Nov 2019
Posts: 1571
Location: Rochester, Minnesota
Tue Apr 06, 2021 2:19 pm quote
whereshaldo wrote:
I did this using thermostat wire. Its a solid core wire which makes it a little easier to push through the body and it solders up with the existing wires easily enough. Just keep the solid core wires in the body.

Hal
Solid wire isn't as forgiving as stranded, to much flexing at will break.
  DoubleGood Vespa T-Shirts  
Post Reply    Forum -> Not-So-Modern
[ Time: 0.1853s ][ Queries: 27 (0.0336s) ][ Debug on ]