yike about repair cost....
but yea - never ever ever touch anything relating to ignition switch or cut-off switch. I've heard too many stories about burnt wiring. leave it alone. any wiring to ignition switch and cut-off switch should always be left alone... it's the most important part of the bike.
all you gotta do is build a simple fuse box (such as Radio Shack project box) with Bosch Relay (optional) and use proper wires with proper rating to handle a certain amount of amperage.
many many many riders are very clueless about wiring. it's amazing how clueless they are about it. it's just as bad as computer users not knowing how to install or delete a program
y people use some cheap thin wires and then simply hotwire it to any wire they can find or simply connect it straight to battery. tsk tsk tsk..... and then eventually, they'll either see their bikes on fire or have to cough up $$$$$$$ towing and repair cost for a new wiring/fusebox/etc.
since you know DIY electronic stuff very well, then you already know you need to calculate how much amperage an accessory (light bar, heated vest, etc.) will need and use correct wiring with correct amperage rating depending on how it's connected - straight to battery or parallel circuit or series circuit. and it's good idea to use a fuse for protection purpose.
another thing that many riders neglect very often - a wiring management. it's very very important to properly wire it from Point A to Point B because most riders just stuff it somewhere and ignore it. Motorcycle creates heat. So that means it will get very very hot inside. Common sense, right? So that's why some wiring will melt and then your bike will be on fire or not work.
A few simple solutions for this -
1. you can use heat-resistant tape (I think this is little expensive but better than burnt-out bike
) and wrap it around the wiring all the way - just the area where it will be close to hot area. Just about all bikes have this kind of tapes on their wiring.
2. you could use wiring with high heat-resistance but I think this option is very expensive and wiring could be very thick. sometimes it can be difficult to try to wire a thick/stiff wire thru somewhere inside your bike that has a very tight space.
3. always use any material with high heat-resistance such as soldering silver, tape, glue, etc. since motorcycle creates a massive amount of heat inside that can go up to around 200+ degree.
I learned my mistake couple days ago :Oops: Since I didn't have anything to properly secure my HID ballast onto my bike frame because Home Depot was closed, I used a poor man temporary solution by using a hot glue. After riding for a couple hours... I found out that the glue had melted off and my ballast fell off and was just hanging on by some wires. Apparently, my ballast creates a tremendous amount of heat and I almost burnt my fingers when trying to put ballast back on. It was definitely much hotter than hot glue. I didn't know it would create that much heat
For now - I'm using some wires to tie it to my bike frame. I need to go to home depot today and find a high heat-resistance, thick double-side commercial-grade tape and some heat foil tape because my tank bag strap is next to it so I don't want my nylon strap to get melted even though my tank bag nylon strap is designed for high temperature but hey.... better safe than sorry!
My mechanic just explained to me that if you use HID kit, it usually comes with ballast because HID requires a large amount of power which is why it's very bright. Ballast converts 12 volts into like 120 volts which is why ballast gets very hot. and you know what's the best part? my HID kit consumes about 50% less amperage than my stock headlight which means I get more juice left over for my accessories. lol I can see how this can confuse some people about the difference between voltage and amperage
I remember in my first year, my motorcycle died several times even though I recharged it several times. It was because both my stock headlight and heated vest depleted the power very quickly. so my mechanic recommended DEKA battery and HID kit upgrade. Now..... NO PROBLEM!
Stock battery is crappy too because it will get quickly depleted if exposed to high heat or cold temperature. it's very sensitive. plus - you have to regularly fill it up with distilled water otherwise it will be permanently damaged as it will get sulfurized
I'm not going to waste 15 minutes just to take out my fairing part and check the battery water level. That's just silly and stupid
The previous owner gave me service maintenance receipts and I see that he had bought batteries twice in almost 2 years! I knew exactly what was wrong. Even though my bike battery is brand new right now... I'm getting rid of it so I just bought DEKA AGM Battery from ebay.