Heated Grips Install - RSTD

[mfb]

I have looked around and have not seen a specific write-up for the install of heated grips for the RSTD. So I thought that I would take a crack at writing something up based on my recent experience.

 

The first thing that I did in preparation for this install was wire up a relay and terminal strip that I could use for power. I wanted power not just for this install but for future electrical accessories (lights, GPS, and communication system). I found great set of instructions for this at the Canyon Chasers site.

 

Attached is a picture of how I installed mine under the seat (Relay.pdf). I tapped into an unused accessory plug that I assume is a leftover from the Venture wire harness.

 

I tried to find something smaller than the terminal strip I used for distribution but it was inexpensive and it works. I have been unable to find the jumpers to energize the next terminal so I just made my own.

 

I decided to retain the stock grips and install heaters from Dualstar. The price was a bargain (29.95 plus shipping) when comparing different heated grip systems.

 

I struggled for a long time with where to install a switch. I didn’t want to spend much money on anything fancy, I didn’t want any bulky box or pod for switches and the RSTD doesn’t provide too many spaces to stick anything. I wanted something that was inconspicuous and settled on placing it in the plastic cover that conceals the frame and wiring that runs to the forks (Switch.pdf).

 

I may regret this location because it isn’t easy to reach but I think the grips will be something I will not need to be flipping on and off frequently. If I am wrong with this location it will be easy enough to conceal and move on to something better when it comes to mind.

 

The next challenge was getting the grips off. I took the counter weights off without a problem and used a small screwdriver and popsicle stick to pry loose the glue from the grips and worked them off.

 

The next big surprise was the ridges on the throttle tube. I wasn’t expecting this and you must apply the heater to a smooth surface. With a lot of patience, a utility knife and a dremel I removed them and installed the heater element.

 

The clutch side heater is about as simple as putting on a piece of tape and routing the wire down the bars. I did use the dremel to rework the chrome colar that goes with the grip to get a snug fit around the wires.

 

I tested everything at this point and it was then that I ran into a snag. I had a short in the system. I called Dualstar. They helped me diagnose that the problem was on the clutch side and they sent a new one right away. They said they test every unit before it ships but I couldn’t see where I could have crimped or nicked anything thing to caused the problem. Regardless they took care of me.

 

Moving on to terminating the wiring and powering things up…

 

I had ran my power and ground from my terminal strip up under the tank to the switch and into the area under the chrome cowling that covers the speedometer display unit.

 

Special Note: Removing that chrome cowling was a royal pain. It was held in place by three Philips screws that were installed with loctite and one head completely stripped out. Thanks heaven it was one on the out side, they are almost accessible. Had the center screw striped out I would still be standing in the garage swearing to myself wondering how to get it out. Needless to say I replaced the screws with Allen head bolts(Cowling.pdf).

 

I soldered all my connections and put them in shrink-wrap tubing to keep things protected from vibration and the elements. The bundle of wires tucked up under the cowling neatly.

 

I put things back they way they were and now I am waiting for the snow to melt and I can actually go for a ride.

 

The heaters work great in the garage but I guess the big test will be in a few weeks when I can get out and go for a ride and see if they overcome the wind chill that my hands feel sticking outside the protection offered by the windscreen.

 

Hope this helps any of you considering the install.