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Adding Extra Length To Some Wiring - Advice Needed?

Discussion in 'Technical Help' started by Thruccy Sean, Apr 12, 2018.

  1. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    Hi all,

    I've been fitting a new exhaiust to my 2012 Thruxton and have run into a few problems. Although I've had it all up and running and it sounds and looks great, i'm really not happy with how close to the exhaust pipes the O2 sensor wires are.

    I didn't think I would have to add to the length of the wiring so that I could route them safely away from the exhaust pipes, the instructions/video tutorial led me to believe I could just re-route them and it'd be fine. But it's not so I've decided to snip the wires, add in some length and then crimp and heat shrink them. Then I'll have enough extra length in the wires to route them safely and it'd be a better job overall.

    I'm simply incrreasing the length of the wire not powering anything extra here but before I plough ahead would this wiring I have be suitable? I'd rather not fit it all only for it to fail on me and I have to do it all again ...

    [​IMG]

    Thanks for the help,
    Sean.
     
  2. youngy

    youngy Active Member

    Oct 30, 2017
    33
    28
    Peterborough
    I really wouldn't extend the wiring on the O2 sensor. It is a variable resistor and any resistance in the joints in the wiring could affect the value seen by the ECU.
     
  3. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    Thanks youngy but I'm at the point of no return now as the 02 sensor wire had already been snipped. Just wasnted to check suitability of this wiring in case there was something else I should have used? :confused: This particular modification has been done by others to lengthen the wiring, it's also included as part of the instructions from TEK where the exhaust was purchased.
     
  4. youngy

    youngy Active Member

    Oct 30, 2017
    33
    28
    Peterborough
    OK good luck
     
  5. StrippleMont

    StrippleMont Senior Member

    Nov 5, 2016
    247
    143
    Sevenoaks
    It will be fine, try to extend it plug end, as near the sensor it will my be HT rated (high temp) cable;)
     
  6. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    Thanks stripple, yes I’ve made the cut up by the plug end rather than down by the sensor that’s in the exhaust.

    I was going to get the cables set up inside tonight and then do the rest out on the bike tomorrow but just wanted to check the cable I’m using to extend will be suitable.
     
  7. TEZ 217

    TEZ 217 Elite Member

    Mar 6, 2016
    1,493
    700
    south shields
    Should all be fine I would think good joints and well shrink wrapped and dont overdue the amount added on.
     
  8. crispey

    crispey crispey creme de la creme
    Subscriber

    Nov 6, 2014
    4,440
    1,000
    sw london
    Just putting this in the mix! How far you going to go!
     
  9. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    Oh no not something else :joy:
     
    • Informative Informative x 1
  10. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    Yeah permanent crimps, butt connector then wrapped. Planned to add about 15” with the wiring, do you think that’s too much?
     
  11. TEZ 217

    TEZ 217 Elite Member

    Mar 6, 2016
    1,493
    700
    south shields
    Fair bit extra , but as you said its been done by others and recommended by the supplier, kind of going to be suck it and see kinda thing now,
    As Arnie would say DOO - IT
     
  12. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    In all honesty at this stage I don’t know. Its taken me a year to get ready for buying the exhaust and when I did finally buy one I didn’t get the one I’d spent a year waiting to get! :p So who knows what’s down the line.

    This exhaust has been a right nightmare though. The video tutorial the guy gets in on his bike in 3 mins! Took me over 3 hours just to get the old ones off! :triumph:
     
  13. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    Maybe I’ll lose a few inches. I was probably overdoing it. I think in Delboys YouTube video he adds about a foot when doing the same thing to his scrambler.
     
  14. Rocker

    Rocker Senior Member
    Subscriber

    May 1, 2016
    251
    113
    Suffolk
    I think soldering the wires together would be better:)
     
    • Agree Agree x 3
  15. TEZ 217

    TEZ 217 Elite Member

    Mar 6, 2016
    1,493
    700
    south shields
    Just add the amount you need to run the wire to where you need it,
     
    • Like Like x 1
  16. crispey

    crispey crispey creme de la creme
    Subscriber

    Nov 6, 2014
    4,440
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    sw london
    @Thruccyboy I'd like to hear your 2into1 sometime, maybe we could do a meet up sometime
     
  17. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    I would’ve normally soldered but advice from others who have done this say that permanent crimps are better in this case as the wires run near very hot parts, so don’t want to risk the solder melting.
     
  18. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    I’ve only fired this one up the once and even with the baffle in it sounded tons better than the stock exhaust. If it still works after I’ve mucked with the wiring I’ll try and get a video ... never sounds great through a recording but might give you some idea.
     
  19. Rocker

    Rocker Senior Member
    Subscriber

    May 1, 2016
    251
    113
    Suffolk
    I thought the O2 sensor wire had a heat protective sheathing and if you wire gets so hot the solder melts it's time for the fire brigade!
     
    • Agree Agree x 2
    • Funny Funny x 1
  20. Thruccy Sean

    Thruccy Sean Active Member

    Mar 14, 2017
    151
    43
    Carshalton, Surrey
    You could well be right, the sensor wire does have something around it in places. I’m just going off Delboys YouTube video for this mod so following his process :)
     
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