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joining two wires

By Rib Eye,
in DRZ400/E/S/SM

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Rib Eye

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What's the best way to join two wires on the motorcycle?

Twist them together, solder, and shrink wrap?

Butt connector, crimp, shrink wrap?

I notice that many connections are made with plug in connectors on our bike, is there a good source for these types of connectors made for MC usage?

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Grand Master

kman780

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Twist, solder, and shrink wrap is and always has been the best way to make a permanent connection.

If you want to be able to remove it, weather pack connections are great but expensive. You can use crimp ends that are weather tight for those.

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Erik Marquez

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Twist, solder, and shrink wrap is and always has been the best way to make a permanent connection.

If you want to be able to remove it, weather pack connections are great but expensive. You can use crimp ends that are weather tight for those.

Solder is ok, and a time honored way. It also creates a stress point, that can fail. Any wire that sees lots of vibration or flexing would be better connected using the crimped connection described above. :ride:

That said I've done both in the past with great success, but always choose the better way when I can. :ride:

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kman780

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Solder is ok, and a time honored way. It also creates a stress point, that can fail. Any wire that sees lots of vibration or flexing would be better connected using the crimped connection described above. :ride:

That said I've done both in the past with great success, but always choose the better way when I can. :ride:

Got it... I normally solder stuff when I am not going to use it anymore, like my kickstand switch.... I think that was my first mod after cutting the fender on my DRZ but can't be sure.

So far its holding up fine. The fact is that on a DRZ there is not a lot of room and if you need to pull it apart you will hate yourself for soldering the majority of your connections....

But if you use a crimp style connection I 100% agree good crimper, not the one that comes with all the ends and in the little plastic tray, and grease the connection. Shrink wrap is always a good idea but some of the new fancy connections have shrink wrap built in now too - VERY FANCY..... ?

Also, soldering stuff takes a little skill if and is fun to watch if someone doesn't know what they are doing and is burning up wires, cursing, etc.... LOL

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CORider63

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Posted (edited)

If the two wires will be permanently connected, I would use solder and heat-shrink tubing. I have never had a solder joint break on a motorcycle or any other vehicle. The key is to be sure that the ends of the wires are very clean, make sure that you make a very good MECHANICAL connection between the two ends of the wire (i.e. Western Union Splice), use a good quality rosin-core electronic solder and just enough solder to complete the joint without allowing the solder to "wick" up the wire.

I have, however, seen a number of times where butt connectors have caused connection problems on a number of vehicles and trailers.

If the two wires need to be able to be unplugged, I have successfully used weather-tight crimp-on bullet connectors from Autozone.

http://www.autozone.com/autozone/catalog/accessories/accProductDetails.jsp?displayName=ElectricalWireConnector&itemId=670-10&navValue=100670&parentId=367-10&productId=318695&fromString=search&itemIdentifier=318695_0_0_&filterByKeyWord=bullet&categoryNValue=100367&store=834&skuDisplayName=Conduct-Tite16-14gauge.157in.bluefemaleweatherproofbulletconnector&categoryDisplayName=ElectricalandLighting&_requestid=1322780

http://www.autozone.com/autozone/catalog/accessories/accProductDetails.jsp?displayName=ElectricalWireConnector&itemId=670-10&navValue=100670&parentId=367-10&productId=421771&fromString=search&itemIdentifier=421771_0_0_&filterByKeyWord=bullet&categoryNValue=100367&store=834&skuDisplayName=Conduct-Tite16-14gauge5/32in.bluemaleweatherproofbulletterminal&categoryDisplayName=ElectricalandLighting&_requestid=1322377

Western Union Splice.gif

Edited by CORider63
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Erik Marquez

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because you know how its done to keep air planes from falling out of the sky. :D

Was thinking the same thing when I replied.. Soldering is for Harleys, Crimping is for aviation and military vehicles,, You think there is a correlation between the two methods that shows up in reliability and failure rate???:lol::D:lol::D:lol:

OK enough Harley bashing.

Either method done wrong will fail.

Crimpers bought at autozone make a really bad hammers and a worse crimpers. :ride:

A cold solder will fail.

Soldering creates a weak stress point in the wire. The wire is no longer flexible as it was designed. These stress points fail. It's not a guess or something seen just on an internet forum :D

Do what works for you :ride:

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William1

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I solder, perhaps because I am old school. I flow the solder up inside the insulation 1/4" to 1/2" to reinforce the connection. I have never had one fail. A benny of this is it slightly melts the inside insulation against the solder, sealing it. It also coats the copper to prevent corrosion. But all this technique is more than simply applying heat and solder. It comes from years of practice.

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CORider63

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I solder, perhaps because I am old school. I flow the solder up inside the insulation 1/4" to 1/2" to reinforce the connection. I have never had one fail. A benny of this is it slightly melts the inside insulation against the solder, sealing it. It also coats the copper to prevent corrosion. But all this technique is more than simply applying heat and solder. It comes from years of practice.

Just make sure that the heat-shrink tubing extends past the the solder in both directions to act as a strain relief and don't place the joint in a position that it is allowed to bend back and forth.

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ptgarcia

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I can't solder very well at all so I usually use crimp connectors. I use decent crimpers but crappy Auto Zone style connectors. I take my time and make sure the crimp is good and cover with Auto Zone crap heat shrink. Never had anything fail yet (including all the electrical I've done on my truck that gets beat on regularly off road). I think the most important thing is you take your time and make sure the joint is good. Expensive connectors and tools are helpful and no doubt better, but not necessarily needed. I wouldn't mind having a nice crimper though, because they do make the job easier.

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kman780

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Was thinking the same thing when I replied.. Soldering is for Harleys, Crimping is for aviation and military vehicles,, You think there is a correlation between the two methods that shows up in reliability and failure rate??:ride:?:ride::D:lol::D

OK enough Harley bashing.

Come on man.... My other bike is a black 2006 HD Road King... It has mostly weather pack connectors... It also has never broken down....

Anyway, in case your interested. Pic of it before a 5 day trip with the wife on the back.

road_king.jpg

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