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I have a set of Oxford Hot Hand heated grip wraps which I'm planning to fit on my DL650 in the next few days.

There seems to be a huge excess of wire connecting all the bits together which will have to be wrapped round the handlebars or tied up. The instructions say very clearly not to shorten the wiring. Can anyone explain why this is? I can't really think of a good reason why the wires shouldn't be shortened but if anyone knows the reason I'd be really interested to know :)

Thanks,

Ed
 
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The short answer: They probably have a good reason for telling you not to shorten the wires.

The long answer: I'm not familiar with the Oxford Hot Hands so I'm guessing here a little. However, I deal with temperature controllers at work a lot so I know in general how they work.

I assume that when you look at your unit there are some larger wires that provide power to the heaters and then some smaller wires which provide temperature feedback to the controller. If they are using a thermocouple for temperature sensing then cutting the wires may cause a problem with the feedback loop. The problem isn't shortening the wires. The problem comes when reconnecting the ends after you shorten the wires. You cannot solder thermocouple wires back together since a thermocouple works by detecting the voltage generated by a bi-metallic junction. If you add a couple extra metals (tin and lead in the solder) into the loop if throws off the voltage generated.

Good luck,

Shawn
 
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Thanks for the reply - yes I guess if they say don't shorten the wires there has to be a good reason but I just wondered what it was. (I think I was one of those kids who always asked "why?" when told to do something!).

The hot-hands are fairly basic, just two wires to each grip and a simple on/off switch with AFAIK no temperature feedback. I guess I will just bunch the extra wire up with a cable tie.

Ed
 

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hot hands install

Nice pics there Stromtro! I also took the Hot Hands challenge and wired up a set as I got my DL back in September and rode thru to the very last day of November here in Northern New England. The Hot Hands helped a great deal. One tip that I might offer. If you run the wires straight back to the battery you can leave the Hot Hands on by mistake and flatten your battery while the bike is parked. Take advantage of the fact Suzuki wired this bike for plug-in heated grips. Connect the power feed for the hot hands to the factory harness connector just behind the top right side of the radiator. If you connect here, the power will be switched with the ignition key and you will never have to worry about forgetting to turn the hot hands off. To make it really easy to connect at this point order a HORN LEAD from your Suz dealer for just a few bucks. It is is a small wire harness that connects the stock horn to the wire loom. Just so happens it fits the factory supplied heated grip connector. Fast easy way to hook up hot hands without having to bodge anything. A tip of the hat to Jack of www.rhinowerx.com for that great tip.

Oh, yes, don't cut the extra wire. Just neatly bundle it and tie wrap it off on a brake hose or the handlebar. It's figured into the resistance of the circuit.

Jeff
 
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Thanks for the helpful replies.

I fitted my hot-hands using a suzuki "horn lead" and the socket behind the radiator so I have no chance of flattening the battery. I didn't shorten the wires just wrapped them up and attached to the handlebars with a cable tie. I still can't really see why the wires shouldn't be shortened though. I would have thought the resistance of the copper wires was negligible compared to the resistance of the heater element, but it's a long time since I did physics at school!

Of course since I have fitted them we have had a few warmer days in London, but will leave them on till the last of the cold weather has gone

Ed
 
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