Tweet
Repairing a broken front brake and auxiliary power connector
Broken front brake and auxiliary power harness connector
A standard 10/12 gauge crimp connector won't hold the bullet connectors correctly
The new connector must be trimmed to match the original
Use a very fine detail tool to remove only the minimum amount of excess metal from the new connector
Can not hold the connector in the vise this way as it will crush
Put a small Phillips screwdriver in the crimp barrel to prevent crushing the connector
Bend the flat side of the new connector to match the old connector shape.
The 10/12 gauge crimp barrel is too big so the harness wire must be trimmed and folded over onto itself to fit
Crimp and solder the new connector and then insert the bullet connectors
Pack the connection with dielectric grease and slide the insulation shield over it
Line up the ears and carefully place the open part of the cover down over the front harness
Test the brake light to make sure it comes on when you squeeze the front brake lever, reinstall the fairing or headlight and go for a ride!
Regards,
Scott
Broken front brake and auxiliary power harness connector
A standard 10/12 gauge crimp connector won't hold the bullet connectors correctly
The new connector must be trimmed to match the original
Use a very fine detail tool to remove only the minimum amount of excess metal from the new connector
Can not hold the connector in the vise this way as it will crush
Put a small Phillips screwdriver in the crimp barrel to prevent crushing the connector
Bend the flat side of the new connector to match the old connector shape.
The 10/12 gauge crimp barrel is too big so the harness wire must be trimmed and folded over onto itself to fit
Crimp and solder the new connector and then insert the bullet connectors
Pack the connection with dielectric grease and slide the insulation shield over it
Line up the ears and carefully place the open part of the cover down over the front harness
Test the brake light to make sure it comes on when you squeeze the front brake lever, reinstall the fairing or headlight and go for a ride!
Regards,
Scott