TCI connectors?

[RockinD]

As the 8 gang and 4 gang connectors for the TCI box seem to be a thing of the past (plus any other specialty types), the best I can do is take each spade fitting and label each for the correct terminal. Have I got that right?
(Thanks Randy for your response)/s

When I get that done and the bike is running good, just spray over that with some of the Plasti-dip rubber sealant? Good to go?

It seems it's really impossible to maintain a stock condition bike. Not that improvements aren't welcomed, just hate to be cheesy about repairs.

[mxmikie]

a lot if import cars use the same connectors

[dbeardslee]

I'd make every effort to find the correct connectors. Spraying it with plastidip will get you labeled as one of those PO's one day . Aside from the obvious, there are electrical tests that are done at the TCI that require access from the back of the plug while it's connected. If you could find an old wiring harness, or the right piece of one, you could always transplant some connectors. I wouldn't be surprised if there are members out there with the proper connectors on a shelf somewhere. Might be worth a PM to Andreas.

[jwhughes3]

Extensions

If someone could source male-female connectors we could build extensions easily to relocate the TCI somewhere else when fitting seats. I am hoping for a miracle

John in San Antonio

[trbig]

Get in touch with Geezer.(Tony) He has just about every connector on the bike in stock. And if not... he may know where to order one.


Tod

[Geezer]

I have these in stock. The ones I carry have the locking tab but if you cut it off, the rest of the plug is the same. I have a few extra of the female 8 prong plugs that I'd let go cheap...

Geezer

[RockinD]

@dbeardslee
I tried Andreas earlier in the week and am sending off for a speedo gear, but that was the only thing he had on my list.

I did find that one of the connectors I bought a while back actually fit the 4 gang side (I have had parts all over the place-until this week), now I'm hoping to check for the 8 somewhere. I'll try Tony if I can't source this elsewhere cause I need another 12 or so assorted pieces plus wire and thought I'd save on shipping if I could get it all in one shot, but thanks trbig.

As an aside, I could not get continuity from any of the 3 white wires at the reg/rec connector today. My entire afternoon has been chasing circuits and this one has made me scratch my chin a few times.

Also, the three whites coming from the stator/alt have a very heavy cloth like outer sleeve to them. Is that per manf? (Didn't open the cover yet to see what's up there.)

[Hey, Tony, muchas grass- was typing while you already caught this. Let me get my list sorted and I'll hit your site.]

[CatatonicBug]

The cloth-like cover on the wires is stock.

Have you looked at the connector behind the fuse block panel? That's the first point of failure for the alternator connections. Mine was melted when I first got my bike. The wires go from there to the reg/rect.

[RockinD]

Stuck on stupid

I guess, the wiring on my bike is bizzaro

[RockinD]

Fourth Try

To post this. This will be a hella lot shorter.

I ran into this at the headlamp bucket while looking at replacing crumbling 30 year old connectors. I traced a 3 wire (R,Brn,Blu) main switch plug with 2 wires- Brn, R/Y coupled to the Brn and all run over to the fuse plug wires. They were separated then into 4.
A jumper was open spliced into the Blu to the Grn of the HL plug.

I have an extra Blk wire out of the harness at the rectifier Brn, Grn plug.

I am not sure where to go next. Any advice is, as always, appreciated.

BTW- looking for the HL bezel/lens assembly...

[dbeardslee]

Maybe this will help. It's a 'dumbed down' wiring diagram, but if you do a search you'll find others on the site. Best advice I can give you is to refer to the wiring diagram and make sure everything is going to the correct connector. Then I'd start going through every connector on the bike and make sure they're clean. If you really want a first class job, get some crimp on connectors and replace them all. I did that on mine after a thorough cleaning, and got a full volt back at the TCI. Pay particular attention to the red/wht wire - that's where the power for the ignition comes from. And don't forget the handlebar kill switch, but be careful when disassembling it - it's got a tiny spring and ball bearing inside that can really fly.

[clcorbin]

As for wiring diagrams, the factory diagrams in the service manual are VERY stupid. They have EVERYTHING on one sheet, so you can't tell what is what.

Thankfully, the service manual ALSO has individual schematics for each circuit (or at least many of the critical ones) in the section that covers that circuit/item. Those are a LOT easier to read as it only has the related "stuff" on them so they are a lot simpler and more logical.

[oldyam80sg]

I have a harness that i have taken off connectors-I can remove that connector if you cant get it -i dont need it.

[RockinD]

Thanks everyone. I'll be placing an order with Oregon Motorcycle Parts today from Geezer. I will be studying that OEM manual starting today also and will likely use up every connector I get. Hmm, more cleaning...

[dbeardslee]

If you're going to crimp new connectors on your wires, do yourself a favor and get a good crimper to do the job. Mikes XS sells one for $24 (Part #35-0008) that does a perfect factory double crimp that looks like this -