SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> how to fix bad connection on connector
/cgi-bin/YaBB.pl?num=1459737389

Message started by springman on 04/03/16 at 19:36:26

Title: how to fix bad connection on connector
Post by springman on 04/03/16 at 19:36:26

I found why my headlight was going off intermittently and thought I fixed but light turns off when I turn the handlebars to the left. I am attaching of the male and female side of the connector. The yellow with white stripe (I think it was) wire is making an intermittent connection and even looks as if it overheated at one time. Is there a simple way to fix this?

The top right hand connection is the bad one.

Title: Re: how to fix bad connection on connector
Post by springman on 04/03/16 at 19:38:29

Here is the other picture. On this picture is the far left top pin. Thanks.

Title: Re: how to fix bad connection on connector
Post by Kris01 on 04/03/16 at 19:41:53

Can you squeeze the female side closed a little bit for a tighter fit?

Title: Re: how to fix bad connection on connector
Post by verslagen1 on 04/03/16 at 19:48:04

I would push the connector out the back side and clean it up 1st.
then squeeze it a bit to make it fit tighter.

there's a little finger that snaps in when the connector is inserted into the plastic thingy. you need to push that in, the the connector will slip out.

Title: Re: how to fix bad connection on connector
Post by oldNslow on 04/03/16 at 19:53:37

The simplest way is to cut that pair of wires off where they enter the connectors and put them together using a male and a female bullet connector so you can still disconnect them if you ever need to.

Should be able to get the connectors at most auto parts stores.

http://www.oreillyauto.com/site/c/detail/CTI0/85429/N0215.oap?ck=Search_N0215_-1_-1&pt=N0215&ppt=C0189

Title: Re: how to fix bad connection on connector
Post by springman on 04/04/16 at 08:54:02

Thanks for responding Versy and Oldnslow. Can't wait to have all that fun taking the tank off again. I'll try Versy's solution first but will probably buy the connectors before getting started just in case I cannot get it to work. Thanks.

Title: Re: how to fix bad connection on connector
Post by springman on 04/04/16 at 08:58:56

Thanks Kris. I did play with the connector a good bit and thought I had gotten it so the female side was a bit tighter but I guess not tight enough. I will definitely play with the connector a bit more before proceeding with more drastic measures.

Title: Re: how to fix bad connection on connector
Post by Art Webb on 04/04/16 at 09:06:02

I used to be able to get in connectors with a straight pick and tighten up the connections, rather than pulling the wire out, but it never seems to last very long, I'd likely just go to the bullets, but then, I'm lazy ;D

Title: Re: how to fix bad connection on connector
Post by oldNslow on 04/04/16 at 09:24:56

293A3C3F2D2A2A480 wrote:

Yup. The little locking tabs rely on spring tension to hold them in the plastic. If they got very hot they probably aren't very "springy" anymore. Might be able to save them, I have done it, but we're talking about a headlight. Having it suddenly blink off on a dark road might not be worth the risk.

Title: Re: how to fix bad connection on connector
Post by springman on 04/04/16 at 10:16:25

You make a good point there Oldnslow. The headlight actually cut out on me on a country road where it was close to pitch black. I immediately pulled off the road, way off but before I could even think of what could be wrong it came back on and thank God it stayed on until I got home. Actually it cut out on me a couple more times but at least I was in well lit areas at the time. And of course it came back on before I could even think of what to do with it.

Title: Re: how to fix bad connection on connector
Post by justin_o_guy2 on 04/05/16 at 09:16:40

Like others, I'd wire around it and use something that will unplug.
Some neat stuff can be cut out of a wiring harness in a junkyard.
Or, the bullet or even the spade connection.
Radio Shack USED to be a handy stop...

Title: Re: how to fix bad connection on connector
Post by Dave on 04/05/16 at 09:36:40

You might try cleaning the problematic terminal with Lysol Toilet Bowl Cleaner. Put a drop or two into the terminal that is causing the problem, and let it work for a few minutes - but don't let it dry. Then flush it out with water in a squirt bottle, and then some brake cleaner.....followed by blowing it out with your air compressor if you have one. Then use a little dialectric grease on all the terminals to help prevent corrosion.

If that doesn't do it....the next step would be to take out the female end from the connector and see if it is deformed - you might be able to crimp it a bit tighter.

If you don't want to do any of those (or they don't work).....I have a Bullet Connector kit and can make you a connector to splice into the wiring harness to bypass that part of the connector.

Title: Re: how to fix bad connection on connector
Post by stewmills on 04/05/16 at 10:41:44

+1 on the dielectric grease.

Also, this involves being really careful and not overheating the terminal, but you could try to add some solder to the "male" part of the connector as to make it a little thicker so it is getting a good connection to the "female" part of the connector if it is fatigued and not as springy as it once was. Just remember that overheating the terminal can cause other things to melt and break loose if you aren't careful.

Title: Re: how to fix bad connection on connector
Post by springman on 04/05/16 at 15:51:38

Thanks for the additional input gentlemen. I actually considered what you described Stu, but I did not want to risk screwing it up further. I tried to get that wire out of the connector but did not have any luck and did not want to man handle it without having a ready alternative if I screwed it up. I scraped at it with a pick and tried to push it tighter and after all that I did add dielectric grease. And it actually works pretty well as long as I do not have to make a slow speed left turn. ;D

Dave, I appreciate the offer for the pigtail but I need to get it done right away to make sure the bike is ready for heading to the Twisted Sisters next week. So, I'll be taking the gul durn tank off again and playing with it. Thanks.

Title: Re: how to fix bad connection on connector
Post by pg on 04/05/16 at 15:59:38

I had the same problem 2 years ago. I had ti by-pass the entire connector with three wires to make it work. I crimped & weather packed them and haven't had any issues since. I hope it works out well for you.

Best regards,

Title: Re: how to fix bad connection on connector
Post by springman on 04/05/16 at 20:38:23

Yeah pq, I'm guessing that is what I will most likely end up doing. I'll probably go buy the connectors and and extra wire (if I don't have any) tomorrow after work so I can get it taken care of Saturday morning.

Title: Re: how to fix bad connection on connector
Post by springman on 04/05/16 at 20:49:35

I just went to look in the garage and I have solid copper wire that looks to be of the appropriate gauge. Is solid copper better than stranded wire or does it matter?

Actually, wire I have may be just a tad thin. What gauge should I use? I'm sure I can figure it out once I have the different size wires in front of me. ::)

Title: Re: how to fix bad connection on connector
Post by verslagen1 on 04/05/16 at 20:54:30

stranded wire flexes, solid does not.

Title: Re: how to fix bad connection on connector
Post by KennyG on 04/05/16 at 20:56:54

Vibration from a motorcycle kills solid copper wire.

Title: Re: how to fix bad connection on connector
Post by springman on 04/06/16 at 07:02:44

OK. Looks like I need to buy some wire. Thanks.

Title: Re: how to fix bad connection on connector
Post by Dave on 04/06/16 at 12:48:33

It looks like you might be able to get new brass pieces to fit into the connectors form this site.....

http://www.cycleterminal.com/motorcycle-connectors.html

Title: Re: how to fix bad connection on connector
Post by KennyG on 04/06/16 at 13:42:23

Dave,

Cycle Terminal stuff is really good.

Kenny G

Title: Re: how to fix bad connection on connector
Post by springman on 04/06/16 at 13:59:04

That is cool. Thanks.

Title: Re: how to fix bad connection on connector
Post by springman on 04/06/16 at 19:21:42

I bought the wire and connectors tonight so I decided to get to it instead of waiting for the weekend. Now that I had the wire and connectors I was not scared to really pry on the faulty connector and I managed to get both the female and male connections out of the connector. I was then able to crimp the female connector so that it make a really good connection with the male connector. I jiggled and pulled on it and no effect on the light so it is done. Thanks all.

Title: Re: how to fix bad connection on connector
Post by Kris01 on 04/06/16 at 20:27:31

NEVER use solid wire on anything but your house! ;)

Title: Re: how to fix bad connection on connector
Post by springman on 04/07/16 at 07:11:35

Thanks Kris. I actually thought that the solid core wire was better. But now that this issue has been explained I do understand. I sure am glad I asked cause now I know better. ;)

Title: Re: how to fix bad connection on connector
Post by justin_o_guy2 on 04/08/16 at 06:33:15

Solid conductor wire,, guaranteed to last long enough for you to be a long way from home.