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  • #1

    Electrical Connectors

    Through some of my electrical adventures I have been having lately I have found some nicked wires and a couple connectors that need to be replaced. I am trying to find replacements (Geezer is pretty much cleaned out) and am trying to figure out what they are called (are they molex?) and how to figure out what size contacts to use inside connectors when I rewire some.

    What is the difference between the pin type and the blade type?

    So yeah, I need some direction.
    Nathan
    KD9ARL

    μολὼν λαβέ

    1978 XS1100E
    K&N Filter
    #45 pilot Jet, #137.5 Main Jet
    OEM Exhaust
    ATK Fork Brace
    LED Dash lights
    Ammeter, Oil Pressure, Oil Temp, and Volt Meters
    Green Monster Coils
    SS Brake Lines
    Vision 550 Auto Tensioner

    In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

    Theodore Roosevelt
    Tags: None
  • #2
    Originally posted by natemoen View Post
    Through some of my electrical adventures I have been having lately I have found some nicked wires and a couple connectors that need to be replaced. I am trying to find replacements (Geezer is pretty much cleaned out) and am trying to figure out what they are called (are they molex?) and how to figure out what size contacts to use inside connectors when I rewire some.

    What is the difference between the pin type and the blade type?

    So yeah, I need some direction.
    Hi Nate,
    if you can't find suitable replacement connectors what you could do is dispense with them and solder & shrinksleeve the wires together.
    Makes for better continuity although a definite pain in the arse for future maintenance.
    And, um, pins is round and blades is flat?
    Fred Hill, S'toon
    XS11SG with Spirit of America sidecar
    "The Flying Pumpkin"

    Comment

    • #3
      Originally posted by fredintoon View Post
      And, um, pins is round and blades is flat?
      I guess someone had to say it....

      One of the connectors I need to fix is on the left handle bar cluster. There are several wires that have nicks on them, but there is plenty of excess wire so I could easily shorten and fix the nicks.

      I would prefer to use connectors. And if someone knows where to find a 12 and 4 (or 16 would be better) pin bulkhead connector so I can fix the broken one on the fairing.
      Nathan
      KD9ARL

      μολὼν λαβέ

      1978 XS1100E
      K&N Filter
      #45 pilot Jet, #137.5 Main Jet
      OEM Exhaust
      ATK Fork Brace
      LED Dash lights
      Ammeter, Oil Pressure, Oil Temp, and Volt Meters
      Green Monster Coils
      SS Brake Lines
      Vision 550 Auto Tensioner

      In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

      Theodore Roosevelt

      Comment

      • #4
        Originally posted by natemoen View Post
        I guess someone had to say it....
        Hi Nate,
        OK then, apart from the different connector shapes what do you want to know?
        Fred Hill, S'toon
        XS11SG with Spirit of America sidecar
        "The Flying Pumpkin"

        Comment

        • #5
          Well, there appears to be different sizes, are the different sizes rated for different loads? What size are the ones we use?
          Nathan
          KD9ARL

          μολὼν λαβέ

          1978 XS1100E
          K&N Filter
          #45 pilot Jet, #137.5 Main Jet
          OEM Exhaust
          ATK Fork Brace
          LED Dash lights
          Ammeter, Oil Pressure, Oil Temp, and Volt Meters
          Green Monster Coils
          SS Brake Lines
          Vision 550 Auto Tensioner

          In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

          Theodore Roosevelt

          Comment

          • #6
            Originally posted by natemoen View Post
            Well, there appears to be different sizes, are the different sizes rated for different loads? What size are the ones we use?
            Hi Nate,
            the larger the pin/blade contact area and the fatter the wire that'll fit in the crimp, the more current they'll take. But I'm sure you know that.
            Remember, Yamaha used the least costly connectors that'd work when the bike was new and last until the warranty ran out.
            You have the option to upgrade.
            Fred Hill, S'toon
            XS11SG with Spirit of America sidecar
            "The Flying Pumpkin"

            Comment

            • #7
              Nate, scroll down to the bottom of this page...



              http://www.mikesxs.net/products-78.html#products
              Try your hardest to be the kind of person your dog thinks you are.

              You can live to be 100, as long as you give up everything that would make you want to live to be 100!

              Current bikes:
              '06 Suzuki DR650
              *'82 XJ1100 with the 1179 kit. "Mad Maxim"
              '82 XJ1100 Completely stock fixer-upper
              '82 XJ1100 Bagger fixer-upper
              '82 XJ1100 Motor/frame and lots of boxes of parts
              '82 XJ1100 Parts bike
              '81 XS1100 Special
              '81 YZ250
              '80 XS850 Special
              '80 XR100
              *Crashed/Totalled, still own

              Comment

              • #8
                That's the stuff Tod!

                Now how about those bulkhead connectors!
                Nathan
                KD9ARL

                μολὼν λαβέ

                1978 XS1100E
                K&N Filter
                #45 pilot Jet, #137.5 Main Jet
                OEM Exhaust
                ATK Fork Brace
                LED Dash lights
                Ammeter, Oil Pressure, Oil Temp, and Volt Meters
                Green Monster Coils
                SS Brake Lines
                Vision 550 Auto Tensioner

                In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

                Theodore Roosevelt

                Comment

                • #9
                  Crimp Tool

                  I suggest getting the correct and best crimping tool that you can find. There are too many cheapos out there that can make your wiring repair worse than when you started. Some of the better ones used to be available from your "tool trucks", but good ones can be had online now. The better crimpers will indent a connector directly in the middle on one side and squeeze the other side to it - rather than a flat squeeze.

                  Still, as was mentioned, soldering and heat shrink is the ticket. The better tool for this repair (for tight places) is the small butane torch with multiple tips.

                  MP
                  1981 XS1100H Venturer
                  K&N Air Filter
                  ACCT
                  Custom Paint by Deitz
                  Geezer Rectifier/Regulator
                  Chacal Stainless Steel Braided Brake Lines
                  Chrome Front Rotor & Caliper Covers
                  Stebel Nautilus Horn
                  EBC Front Rotors
                  Limie Accent Moves On In 2015

                  Mike

                  Comment

                  • #10
                    Nate-

                    Vintageconnections.com. But, those are original connectors. You're too sharp of a guy to use old technology. I re-did my harness on a GS650, and used the GM Weatherpak connectors. I love them!
                    1979 XS1100F
                    2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

                    Comment

                    • #11
                      Originally posted by MPittma100 View Post
                      I suggest getting the correct and best crimping tool that you can find. There are too many cheapos out there that can make your wiring repair worse than when you started. Some of the better ones used to be available from your "tool trucks", but good ones can be had online now. The better crimpers will indent a connector directly in the middle on one side and squeeze the other side to it - rather than a flat squeeze.
                      Ok, lets play the "What's a Good Crimpwr Game"

                      Originally posted by IanDMacDonald View Post
                      I re-did my harness on a GS650, and used the GM Weatherpak connectors. I love them!
                      The other ones lasted 35 years, I am not going to go overboard here.
                      Nathan
                      KD9ARL

                      μολὼν λαβέ

                      1978 XS1100E
                      K&N Filter
                      #45 pilot Jet, #137.5 Main Jet
                      OEM Exhaust
                      ATK Fork Brace
                      LED Dash lights
                      Ammeter, Oil Pressure, Oil Temp, and Volt Meters
                      Green Monster Coils
                      SS Brake Lines
                      Vision 550 Auto Tensioner

                      In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

                      Theodore Roosevelt

                      Comment

                      • #12
                        Okay, go with the barrel crimp connection. Best crimp hands-down. I'll let u borrow my crimper to save u some money. I bought tons on those single, double and tripple bullet connectors with sleeves from the site.

                        and if you're looking for those 12 & 16 pin bulk molex connectors, Mauser and digikey sell them for a few bucks.
                        1979 XS1100F
                        2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

                        Comment

                        • #13
                          MikesXS is pretty freaking proud of their shipping......could put that stuff in a envelope and mail it for probably less than $3, $11 my A$$

                          Ok, so I am trying to find a crimper, and since no one really had any suggestions I was browsing amazon and have some possibilities and want opinions.

                          http://www.amazon.com/gp/product/B00...=AZFBKZY6N6YFG

                          http://www.amazon.com/gp/product/B00...A10EAPE4CAYC9P

                          http://www.amazon.com/gp/product/B00...A2F13KK758WMXQ

                          http://www.amazon.com/gp/product/B00...=ATVPDKIKX0DER

                          http://www.amazon.com/gp/product/B00...A1UMBRA5ZTBCX8

                          Which one, or if you have a better suggestion let me know.
                          Nathan
                          KD9ARL

                          μολὼν λαβέ

                          1978 XS1100E
                          K&N Filter
                          #45 pilot Jet, #137.5 Main Jet
                          OEM Exhaust
                          ATK Fork Brace
                          LED Dash lights
                          Ammeter, Oil Pressure, Oil Temp, and Volt Meters
                          Green Monster Coils
                          SS Brake Lines
                          Vision 550 Auto Tensioner

                          In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

                          Theodore Roosevelt

                          Comment

                          • #14


                            Terminal Crimper Tool

                            This one should do the job. It's also from Mike's.

                            Do not solder these connections. Over time, they will break. A good crimp connection is most appropriate for this application. I have used Mike's connectors in the past and they did appear to be OEM quality.
                            Marty (in Mississippi)
                            XS1100SG
                            XS650SK
                            XS650SH
                            XS650G
                            XS6502F
                            XS650E

                            Comment

                            • #15
                              Originally posted by jetmechmarty View Post


                              Terminal Crimper Tool

                              This one should do the job. It's also from Mike's.
                              I try to avoid buying overpriced Chinese crap.
                              Nathan
                              KD9ARL

                              μολὼν λαβέ

                              1978 XS1100E
                              K&N Filter
                              #45 pilot Jet, #137.5 Main Jet
                              OEM Exhaust
                              ATK Fork Brace
                              LED Dash lights
                              Ammeter, Oil Pressure, Oil Temp, and Volt Meters
                              Green Monster Coils
                              SS Brake Lines
                              Vision 550 Auto Tensioner

                              In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

                              Theodore Roosevelt

                              Comment

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