need help with repairing wires

[Tang]

What is the best way to repair wires?

without buying a whole new wire harness!

i want to get my bike running asap!

[ecpreston]

soldering iron?

[Tang]

i was thinkign about stripping them.

then tieing them together

then cable tape them individually?

i guess sodering is good?

[beRto]

i was thinkign about stripping them.
then tieing them together
then cable tape them individually?

I don't think that is gonna cut it; electrical tape is not a long-term splicing solution. You need to buy some proper electrical connectors and attach those to each end of the splice. This will make sure the wires don't come apart with vibration.

[GeeP]

Go down to your local auto parts store and buy some of the proper sized crimp terminals and a crimping tool.  Shouldn't set you back more than about $15.

The connectors look like this:



and install with this:



The color of the connector denotes the size range, be sure to get the correct connector for the wires you plan to connect.

[Tang]

Thanks!

You guys are a life saver!

i love this forum!

[Kurlon]

If you can, find a friend who's good with a soldering iron.  Solder in splices, and heat shrink them to keep moisture out.

[ben2go]

I use crimp connectors without the plastic cover and shrink wrap them to keep out moister.Just make sure the gas tank is removed and the carbs are covered,if you use a flame to shrink the tubing.

[Tang]

I'll take pictures tomorrow i mean later on today lol its 1:31 AM lol of what i'm tryin to connect back together.

and heat shrinking is?

i'm still new with all this 

[ben2go]

I'll take pictures tomorrow i mean later on today lol its 1:31 AM lol of what i'm tryin to connect back together.

and heat shrinking is?

i'm still new with all this 

Heat shrink tubing shrinks with heat from a small flame,ie cigerette lighter.I prefer to use a heat gun or hair drier that gets really hot.Don't worry about being new to mechanics or motorcycle.We all started some where and forums help and make it easier some times.

Here's the heat shrink I use.
http://www.radioshack.com/product/index.jsp?productId=2102875&cp=&sr=1&origkw=heat+shrink&kw=heat+shrink&parentPage=search
Here's the crimp connectors I use.
http://www.radioshack.com/product/index.jsp?productId=2103494&cp=2032058.2032231.2032283&pg=3&parentPage=family

[Tang]

okay i have 4 wires that were cut off

do i crimp them all individually?

and after i do that

do i just slip the tube over them and then hold a flame under the tube till it starts melting to the wires?

[beRto]

okay i have 4 wires that were cut off

do i crimp them all individually?

and after i do that

do i just slip the tube over them and then hold a flame under the tube till it starts melting to the wires?

You will need to crimp each wire individually. The heat-shrink tubing should go on before you make the crimp (otherwise it won't go on unless you cut it, which is not ideal): put the tubing on the wire and slip it away from the joint. Do the "shrinking" part after you make the splice.

In this case, I'd consider a piece of tubing for each individual splice and perhaps a larger piece holding them all together. This would depend on how susceptible they look to vibrations, moisture, etc.

[sledge]

Solder the joints, then use heat shrink sleeving then wrap in black insulation tape. Do it neatly and it will be an invisible repair with no chance of a poor connection or corrosion issues in the future.

[ohgood]

Solder the joints, then use heat shrink sleeving then wrap in black insulation tape. Do it neatly and it will be an invisible repair with no chance of a poor connection or corrosion issues in the future.

I like to put vaseline over the solder joint, then put the heat shrink on, starting at either end with the heat. Makes a squishy bubble of gel if you do it right, then the middle, and it's pretty impervious to water/stuff.



+1 on the solder vs connectors.

[GeeP]

c'mon guys!  He's not splicing the power bus for the primary flight computer on a 777!

There are crimp connectors all over the GS500 from the factory.   

[sledge]

c'mon guys!  He's not splicing the power bus for the primary flight computer on a 777!

There are crimp connectors all over the GS500 from the factory.   

hahaha....we are perfectionists mate 

[Tang]

i think i'mma going with the crimp idea lol i'll take a picture after i'm done today probably take me 4 hrs. haha  since i'm such a noob.

[GeeP]

lol Sledge.   

Tang, after making the connection, be sure to test it by pulling on each end gently.  If it doesn't come apart you're golden.  Be sure to use a properly sized connector and you shouldn't have any problems.   

[Tang]

awesome yeah i'll be sure to do that after i get out of school lol

on the sizing how do i go about that?

[GeeP]

The package of terminals will give the wire sizes the terminals are designed for.

Color coding is also useful:

(Off the top of my head)

Red: 22-16

Blue 14-10

Yellow: 10-8

The stripping portion of the tool will have the wire gauges stamped next to the correct stripping hole.  Use them as a guide to determine the correct connector.  For most wires on the GS, red connectors will do the job.