The Toolkit Thread

Discussion in 'Equipment' started by hilslamer, Sep 2, 2007.

  1. theksmith

    theksmith complete n00b

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    since i started a storm back when i suggested you might make jumper cables out of 14 gauge extension cord... figured i'd post what i ended up with:

    i bought a nice set of "8 gauge compact jumper cables" from rockymountainatv, they are quality stranded wire and good flexible insulation. but they were 8 foot long and the clamps were pretty bulky... here's what they looked like when i got them (the bag in the pic is 9" square for reference):

    [​IMG]

    i cut them down to 5 foot length, which i think is plenty for most situations involving a bike. then i cut off the existing large clamps and soldered on new smaller clamps from radioshack and used some heat-shrink on the connections as well. here's how they came out, and are much more compact and easily storable on the bike:

    [​IMG]
  2. DRONE

    DRONE Dog Chauffeur

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    Wow, them's are nice! :clap

    Maybe you should mass produce a few hundred and start a Vendors thread!
  3. HaChayalBoded

    HaChayalBoded Brooklyn Bored

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    anyone using a jesse rear compartment?

    For months and months I was looking at an old 15 cassette case logic case thinking to myself, man that thing would fit perfectly into the jesse compartment, would make putting tools in and out a helluva lot easier....

    So since I had the compartment in the kitchen this evening fitting a new rack to it I realized I had never checked the fit....

    Off I go to grab the cassette case and it slides in like a glove. The door won't close completely with the actual plastic cassette holder in it, it's about 1\8th of an inch too long, but the height and width are perfect. Out comes the inner plastic thingy, tools are dropped in the case and I slide the case right in. Poifect, now I can actually grab the whole lot out and once instead of reaching in and feeling my way around for shit, or removing everything just to get to the flashlight that always makes its way to the other side of the box.

    The case (with internal plastic tray) is 12"x5"x3".

    Here are some pics of the Case Logic CL-15 cassette case (you can probably find em on eBay. Actually, you can probably just search eBay for 15 cassette case and most of them are the same size, I see a few now labeled as TDK and other brands, the TDK is pleather (easy to waterproof).
    http://cgi.ebay.com/TDK-Leatherette...QitemZ350210944349QQcmdZViewItem#ht_500wt_956

    [​IMG]

    [​IMG]
  4. hilslamer

    hilslamer 2XRedheadedstepchild

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    Have you actually run a test with them, firing a dead bike? I have had really poor luck with motorcycle jumper cables, in many different forms. The best had their own notched-ring connectors that you had to install to gen the dead bike to fire at all...clips and the like have never seemed to work for me...
  5. HaChayalBoded

    HaChayalBoded Brooklyn Bored

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    I can not see those clips holding well for most bikes, but for some where you get to the battery from the side in might work great if you can get in the hole on the side where the battery bolts screw into.

    The ones I put on my cables and my mini jump box have a round notch on the tips of the clips in order to grab the battery bolt. They work the best and I have 5 different types of alligator clips lying around here that I bought and removed from other cables and the original cables from the jump box, most of them suck.

    I'll have to take a pic of the ones I found work best on a variety of bikes.

    true or false, copper connectors work better than standard? The ones I ended up using were copper.
  6. hilslamer

    hilslamer 2XRedheadedstepchild

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    IME, the contact area(and therefor the current-carrying capacity) has been far more important than the materials involved. Ideally it would all be gold, right?

    It just seems like with motorcyles and their batteries, there is so little surplus of juice available that the losses incurred int he jumpers, poor connections, etc are just too much to be of use to the dead bike. It's made worse by all of the light flywheels, 11.5:1 compression and teensy starter motors of modern bikes - or so it seems.
  7. Motoriley

    Motoriley Even my posing is virtual

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    I've used two different sets of cheap ass jumper cables and never had problems jumping my old KLR or my old GL1200 Gold Wing. As long as they are making good contact they work.
  8. MrPulldown

    MrPulldown Long timer

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    I see two issues with thye cut down jumper cables.

    -the two clamps need to be spread apart. The battery terminals on most biek batts are on the opposite end of the battery. Batteries being about 6 inchs long, those clamps need to span the distance.

    -those clips might not be able to carry enough amps.

    I recently made a set very similar, and used pretty big aligator clips. I ran into both issues. I needed to cut and spread the two wires. Easy to do since mine were not shrink wrapped. Also when firing you could hear somethign click. I assume it was my regulator recifier. decided against using my set up, afraid the low amp capacity jsut made come capacitor work really hard on the bike.
  9. MrPulldown

    MrPulldown Long timer

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    Sure that is stop leak. Paired with the lighter I have another idea what that is.
  10. RandyB

    RandyB .

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    It looks like this thread is about to be more useful than entertaining: Someone stole the tools off my GS.
  11. Motoriley

    Motoriley Even my posing is virtual

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  12. Pete O Static

    Pete O Static Adventure Seeker

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    I stole this idea from powerlet who market these for $100

    [​IMG]


    Using 10 AWG wire, four 45 amp power pole connectors, two ring connectors and two alligator clips, I made the same thing.

    A short pigtail goes to the battery with ring connectors. Two 45 amp power pole connectors go on the other end and reside in a discreet but accessible location.

    [​IMG]

    The actual cables sit under my seat. I simply plug them in to the pigtail with the powerpole connectors and have the alligators for the donor or receiver battery.

    [​IMG]


    Close up of the powerpole pigtail. I also charge through this.

    [​IMG]
  13. Poolside

    Poolside Syndicated

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    <BR>
    Nice work. Love those Anderson quick disconnects. I rigged up a set of 350A quick disconnect jumper cables similar to what you have there, for a boat.

    If anyone is interested in the connectors Pete used above:
    http://www.andersonpower.com/products/singlepole-connectors.html
    Also, search for: anderson connectors on eBay.

    <BR>
  14. markjenn

    markjenn Long timer

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    There's a tradeoff when you start adding dedicated jumper pigtails to the battery. You're increasing convenience for jumping, but you're also adding another heavy-gauge unfused wire that can burn your bike to the ground if it ever goes adrift and shorts. And many battery installations are not friendly to adding another set of ring terminals to the battery posts.

    - Mark
  15. Pete O Static

    Pete O Static Adventure Seeker

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    Hi Mark

    Interestingly, I am fussing over that exact situation. I am thinking of an inline fuse but it would need to be pretty hefty to allow boosting. Not sure of the initial amperage during a boost but I would imagine it is north of 50 amps.
  16. rbomb

    rbomb Rather Be On My Bike

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    Just found this thread, great info here. Very good work. Thanks for all your effort.
  17. markjenn

    markjenn Long timer

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    Most bikes have pretty easy access to the battery (often just raise the seat) so a set of motorcycle-specific cables (either commercial or homemade) with 10awg wire and smallish clamps on both ends is probably the way to go. No pigtails on the bike, no extra ring terminals on your battery making battery connection more difficulot, no extra wiring to short, and the jumpers can be used on your buddies bike too.

    If the battery is unusually hard to get to, then I might consider some kind of pigtails or other way to get to the battery. For example, my early-prod R1100S has a terribly-hard to access battery, but rather than pigtails, I upgraded it to match the later models which have have a positive battery post through the starter cover.

    I started an electrical toolkit thread a week or so ago here:

    http://www.advrider.com/forums/showthread.php?t=510722

    - Mark
  18. Poolside

    Poolside Syndicated

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    <BR>
    Get a big ass fusible link.

    <BR>
  19. krehmkej

    krehmkej Been here awhile

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    After reading all this, I made up a 6-foot jumper set using 10-ga speaker wire. Looked at all kinds of clips, but settled on simple ring terminals. Any bike I have ever seen has the same 6mm battery bolts so they should be toe smallest and have the maximum ampacity.
  20. Motoriley

    Motoriley Even my posing is virtual

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    Do you hold the ring terminals to the posts or do you actually bolt them on? I would be worried that if something went wrong with a defective battery or wiring that I couldn't disconnect very quickly.