HOT GRIPS 203 (HW - Hidden Wire) User Manual
Page 2
Some electrical systems cannot handle the power requirements of heated grips
and the headlights at the same time. The model "HW" Hot Grips® will produce 8
watts on low and 15 watts on high for each grip. The ceramic resistor consumes
a small amount of wattage, so the entire kit will draw 1.66 amps on low and 2.5
amps on high.
Some handlebars are slightly oversize and generally it is unwise to try and force
the Hot Grips® on. Better to file down the oversize handlebar until the grip can go
on without force.
EPOXY INSTALLATION ONLY: Obtain a two-part slow-curing epoxy, such as
Duro, Devcon, Borden, JB Weld, PoxyWeld, etc. Make sure it is not the quick cure
type, such as a 5-minute epoxy. We need the slow cure (6-8 hours +) because
generally these epoxies are good for service up to 250 degrees F., whereas the 5-
minute quick cure type epoxies are generally good for only 200 degrees. Do not
use any other method to install. We have tested everything else, and they don't hold
up under the stress and strain, torque loads and heat that is present. (Do not use
silicone seal, crazy glue, gasket cement, weatherstrip adhesive, etc. None of them
will hold reliably under severe riding conditions!) Check that the grip will slide onto
the handlebar without effort. It is normal to find you have a loose fit, to have the
small gap filled with the epoxy. If it is not a loose fit, do not force the grip on. Your
handlebar diameter isn't .875" and must be filed down until the grip fits on without
excessive force. Some metric handlebars we have seen are up to .020" diameter
oversize.
A full length pencil is helpful as a tool to spread the mixed epoxy inside the grip
interior, and on the handlebar. Use a very light coat, and push the grip on 75%
and remove, then redistribute the epoxy with the pencil and remove any excess
quantity. Then install grip 100%, and again remove any excess epoxy. Be sure
the grips do not interfere with any of the handlebar controls or the thumb-throttle
lever. If there is interference, use a new single-edge razor blade to trim the grip
as necessary, using care not to cut near the black lead wires that exit the grip.
Allow to fully cure per the epoxy's instructions, or you may quicken the cure by
temporarily wiring the grips in "series" per the diagram below, and wiring them to
a 12v. car battery, or battery charger with a minimum of 3 amps charge rating.
The epoxy will set up firm in about 30-45 minutes. Allow grips to cool off, and test
epoxy for hardness where it oozed out of the grip. Do not twist the grip to test the
epoxy as it is curing, as this will compromise and weaken it.
SWITCH AND RESISTOR: The switch can be located at any convenient
practical location for your left hand that doesn't interfere with safe vehicle op-
eration. (Note that the orientation of the wires in our wiring illustration to the
"Hi-Lo" switch plate is correct because of the switch's internal action.) Drill a
1/2” hole to install switch.
5.
Epoxy the grips in position as outlined further in the instructions.
IMPORTANT: DO NOT drill an "air-escape" hole in the model "HW" grip's
ends or damage will result. There is no need for the air escape hole since the
air can exit where the wires come out.