Ok, here's the final test fit of the windscreen with neoprene R/C car fuel line as trim.
Now here comes the part that separates the men from the boys, wiring it up. I'll preface this section by saying that if you have NEVER soldering anything, enlist a friend for soldering the main harness connector. The pins are very close together and demand a bit of precision to solder correctly. That said, I did this is less than an hour with a sleepy puppy trying to cuddle with me every chance she got for me to sit still.
For the job you're going to want a low wattage iron (I used my 25watt) and hair thin solder (I used .022).
Start out by soldering the wire to the designated pin from the schematic I posted earlier. An armature such as this one will free up your hands. I'd venture to say this job could not be completed without one.
Slip a piece of heat shrink tubing over the soldered connection. You can pick up heat shrink from any electronics supply store, the web, or in a pinch Radio Shack. The stuff I had laying around was a bit thick for the job, I could have made life a bit easier on myself by buying shrink for a higher gauge.
Use your trusty Bic to apply some heat and voila, a well insulated connection.
Now... do this a lot more. One VERY IMPORTANT NOTE: Start from the center of the harness connector. Don't start on the edges and work your way in or you'll have no way of getting the iron on the inner pins. You'll eventually end up with this
I marked each wire so I could easily identify it without having to see the harness clearly. Also, the little wire leader will allow you infinitely more room to work than trying to wire up your entire schematic directly to the pins. Multiple splices with the Trailtech connectors and such in the way would make a difficult soldering job even harder.
TIPS: When you shrink the tubing with your lighter, it's possible you will get carbon on the adjacent pins. Wipe it off with a rag or you will get weak connections.
I used 18 awg wire. Any thicker and I don't think I would have been able to fit the wires so close together.
Call me paranoid but after I wired the 12v constant power and ground I went out to the garage and plugged the connector in. I used a bulb tester to make sure my orientation was right before I soldered any more wires. Use the old carpenter's adage, measure twice cut once. To get this thing done and realize it was upside down... I probably would have set the bike on fire and moved to Mexico.
