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Front Brake Harness Connector Repair

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  • Front Brake Harness Connector Repair

    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
    -- Scott
    _____

    2004 ST1300A: No name... yet
    1982 XJ1100J: "Baby" SS Brakes, '850 FD, ACCT
    1980 XS1100G: "Columbo" SS Brakes, '850 FD, ACCT
    1979 XS1100SF: "Bush" W.I.P.
    1979 XS1100F: parts
    2018 Heritage Softail Classic 117 FLHCS SE: "Nanuk" It's DEAD, it's not just resting. It is an EX cycle.
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