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The wires are accessed through these small panels in the back of the switch boxes.
The hand controls must be put into place to determine proper position. The holes must thenbe drilled for the wiring. The trick is, to make sure the holes are large enough to accommodatethe wires, but no so large as to protrude from the control clamps or compromise the integrity ofthe handlebars. Drilling holes in a round piece of tube can be tricky, so have some patients.Also, a Dremel tool works well to shape the holes and remove any burs before you run the wires.Burs are evil… They can cause a short and drive you nuts.
A couple of “To-Do’s”. Put the wires through the bars in pairs, and twist them togetherafter you get them out of the bars below the bar clamp. This will make it a lot easier to I.D. whichwires from the bars go to which wires on the harness.
The following schematics show how the bike is actually wired. In addition, there are somequick guides to understanding the basic principles of electric circuits. You may find this handy.One of the issues we ran into using Joker’s Controls is that the high beam switch is a push button type, ratherthan a rocker switch as indicated in the Handlebar Wiring Diagram. This means you mighthave to think about which wires to hard-tie together to make the beast work properly.
There is some crossover with the other systems in these diagrams. For example, power to thespeedo is usually supplied here, however, the wire routing between the speedo, the calibrationbox (if you have one) and the sensor is not. Remember, not all bikes will be wired exactly the same.Some bikes have 2 horns – some have none. Some bikes have rocker switches, some push button. Theidea here is to give you some idea of what you might be in for when you build a your own bike.
Backbone Wiring Diagram Ignition Key Wiring Handlebar Wiring Basic Electrical Principles Module T-Shooting Lights Accessory Circuits Flow Diagram Lights Circuits Flow Diagram Ignition Circuits Flow Diagram
Connection between all the wires is typically to solder them, and insulate the connections withheat shrink (which will dictate you attain a soldering iron and heat gun.)Today however, there are a lot of crimp style connectors on the market that will do the jobnicely. One recommedation – the wetter the climate you are in, the better off you are to solderthe joints.
We’ll hit the speedo, ignition, and charging system next.
Later – Digital
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