lenghtening a wiring harness

[Jerry]

Any tips, tricks, do's or don'ts.

Do you try and keep the wires as short as possible by running thing down the middle of the floor or down the side so as not to step on them?

Do not use the harness wires for lights, fan etc (just cut those wires short and hot shrink the ends) and make your own circuts?

Do you  mount the speedo, cut all the wires to it and start lenghten them one by one or go one at a timeto start?

Maybe this could be like a how to topic.

[fabr]

On this current build I am using ALL the busa bike switches and circuits.I'll just run the OEM harness to relays for the higher than stock amp draw stuff like fuel pump,fan/s,lights,etc..

[Rick S.]

I also use all of the original switches, circuits, and relays. I run the extended wire bundle on the underside of the upper right side rail. I Extend one wire at a time. Solder and double heat shrink all connections. I replace the side stand switch with a toggle switch and I also toggle switch the service check short circuit (for the diagnostics on the original gauge cluster)
On some bikes you will need the stand up, (switch actuated) in order to make the diagnostic features of the gauge cluster work. You need the short circuit to reset the diagnostics after the check.

[Voodoochikin04]

i cannot stress strongly enough the importance of a haynes or equal manual for the bike. most include exploded full color wiring diamgrams and they are worth more than their wieght in gold.  and at 32$ you cant go wrong.

[fabr]

good point.

[Admin]

Jerry has a diagram, But a very good point for others...Polaris supplies full wire diagram in the owners manual... The way it should be..

[Jerry]

This is the next thing on the list. I need to figure out  what needs to be lenghtened and what i can do with out. I speedo alone has 16 wires to it and the key switch has 5, so this will take some time.

[Doug Heim]

I have over 40 wires running from front to back on my recent build.

Do not use lighter wire or a lighter guage as well. Its the size it is for a reason!