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2009-05-15 Electrical connector broken

dcarver's picture
published by dcarver on Thu, 03/24/2011 - 19:31
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2006 Yamaha FJR1300 - KrZy8

...need advice  

Posted 15 May 2009 - 10:35 PM

After a burned wiring loom, and subsequent main harness replacement, KrZy8 had an intermittent high beam, and by association, HID Soltek lights.

Curious, some times the high beams would work, other times not. Hit a bump, On. Bump again, off. Clearly a loose connection. Logical to assume the tech who installed the main wiring harness was at fault.

Take CrZy8 back to dealer for new front tire and hi beam headlight fix.

Pick up CrZy8 a day later, check hi beam and it no workie! Phook! SM calls tech to front desk, he wiggles wires under left front inner cowl, hi beams work, don't work. Hmmm. Tech states he did not remove center, left, or right plastic... so must be an existing problem.

Here's the thing. I trust this guy. My age, we've talked, he knows I'm not full o'Shit like ya'll do, and is genuinely concerned. It's Friday late afternoon, he won't be back until Tuesday, and I've already traveled in truck+trailer 35 miles and have Sat, Sun, Mon to play. So load up CrZy8 to take home and see what I can do.

Here is what I find, after removing the left lower fairing... a broken connector.

I think this most likely happened during my deer strike, and the tech missed it..

Here is the connector.. obviously broken, with the a reddish wire halfway out.. the high beam wire..

So then.. Questions are - What's the best option based upon the cheap factor? I don't feel this is the dealer's issue, this wiring was not part of the main harness replacement. And I don't want to pay for a new sub-harness..

  1. Is the plastic connector available via other sources, then stuff the wires back in?
  2. Use PosiLock connectors and individually connect the wires?
  3. Other ideas?



Damn.. Karma bites my ass for posting used oil, filter, and tire threads. fuck.gif

 

Submitted by dcarver on Thu, 03/24/2011 - 19:32.

Posted 16 May 2009 - 07:25 AM

Carver: I use some yamaha OEM connectors at work. I'll see if I can find this one for you, if my source has them available.

Can you give me a photo head on from the front that shows the pins, and a shot from the back showing the wires going in. Also some shots of the mating connector would be good for comparison.

All the wires and terminals look in good shape. You should be able to take a *very* small flat blade screw driver and release the terminals one by one. There's a little clip lock accessible from the non-wire mating side. You can then clip them into the new plastic mate.

*edit*

After a quick look, this may be a match. Check the dimensions:

Submitted by dcarver on Thu, 03/24/2011 - 20:26.
QUOTE (slapnpop @ May 16 2009, 07:25 AM) <{POST_SNAPBACK}>

Carver: I use some yamaha OEM connectors at work. I'll see if I can find this one for you, if my source has them available.

Can you give me a photo head on from the front that shows the pins, and a shot from the back showing the wires going in. Also some shots of the mating connector would be good for comparison.

All the wires and terminals look in good shape. You should be able to take a *very* small flat blade screw driver and release the terminals one by one. There's a little clip lock accessible from the non-wire mating side. You can then clip them into the new plastic mate.

*edit*

After a quick look, this may be a match. Check the dimensions:

Hey Slappie, Thank You! Damn doode, another guy on the 'buy him dinner or a hooker' list! ohmy.gif
Do these pix help?

Call me a purist, but I'd rather use an OEM connector or EQ than to splice and dice..

Thanks again for helping...

DC

Submitted by dcarver on Thu, 03/24/2011 - 20:43.

Posted 17 May 2009 - 09:54 AM

Curiosity got me to looking at my deer strike fotos from 2007. Guess what I found?

and here is the very same connector!

Walked away :) Posted ImageIs it really crashing if you don't fall down?--

Submitted by dcarver on Thu, 03/24/2011 - 19:36.

Posted 17 May 2009 - 11:59 AM

Thanks for all the great suggestions! clapping.gif

QUOTE (JamesK @ May 15 2009, 11:17 PM) <{POST_SNAPBACK}>

Jim from EasterBeaver is based in Japan, and can source many OEM connectors. If you don't find a suitable one on this page you could drop him an email.

Connectors

Wow - he has really neat products and cheap too.. There goes the credit card again...

QUOTE (Toecutter @ May 15 2009, 11:49 PM) <{POST_SNAPBACK}>

I think I'd do the Posi-lock thing, and I have some I can send you if you want 'em....

Thanks Toe, I have some Posi's and may end up using them.. Although I'd like to have it all be in one connector.

QUOTE (OCfjr @ May 16 2009, 12:46 AM) <{POST_SNAPBACK}>

I think I'd go with this - Molex connectors

Or you could really go low end trailer park and use a flat trailer hitch wiring connector. dribble.gif

Molex - maybe they've improved since the mid 80's when I was using them for power plant intstrumentation work. They were problematic, in that the female connector would 'spread' after time, causing poor connections. And, I do have about 4 of them trailer wiring connectors laying around... laugh.gif

QUOTE (Silent @ May 16 2009, 06:21 AM) <{POST_SNAPBACK}>

Actually bud, I've got a couple old XS11 harness bits that I recently aquired. How many pins are there? I can see if I might have something you can use as a replacement. Should be able to pop the wires out of the old plug and pop them into the new.

Silent, 13 pins, see foto's above. I'd be surprised if the same connector was used back in the day, but hey, it's worth a look!

QUOTE (slapnpop @ May 17 2009, 08:48 AM) <{POST_SNAPBACK}>

In a quick online glance, they weren't in my supplier's online catalog.

This source who I'm not familiar with, just found with google seems to have the same series of connectors, they show an 8 pin. 13 pin is kinda rare.

I do have a some 6 pin connectors, both male and female. I could send you a pair of each on Monday. I'll also check the paper catalogs just to be sure.

Slappie, is this same connector, pix stolen from EasternBeaver

or

Submitted by dcarver on Thu, 03/24/2011 - 19:36.

Posted 18 May 2009 - 02:07 AM

QUOTE (slapnpop @ May 17 2009, 03:45 PM) <{POST_SNAPBACK}>

The one on the bottom looks like your guy. Right series terminals and everything.

Don,

I tend to agree with Slappy, except for the black plastic this looks like a dead ringer for your replacement part. Buy two of them, their cheap!

While you are at it, get this connector too (.110 connectors), it fits on the heated grip controller power line.

That is a good place to pick up a signal wire for a driving light relay. It will keep your driving lights off until you fire the engine.

The shipping price should be the same for 1 set or all 3 sets.

Good luck! smile.gif

Brodie

Submitted by dcarver on Thu, 03/24/2011 - 20:32.

Posted 28 May 2009 - 08:14 PM

Thought I'd post an update to this thread..

Guess what arrived today? An Eager Beaver,

All the way from Japan?

The parts

Close up view of new connector

When I first looked, it didn't seem right.. but then again... it Fits!

Old connector coming apart. I used a small set of dykes of cut the plastic away, after first taking notes of the wire location. The wires on either side don't necessarily match color code..

I cleaned corrosion off the males and coated with dialectic grease.

The finished product, and everything works!

Many, many Thank You's to all that helped, provided advice and words of encouragement! I really appreciate you help!

yahoo.gif

Submitted by dcarver on Thu, 03/24/2011 - 19:38.

Posted 29 May 2009 - 07:39 AM

QUOTE (Silent @ May 29 2009, 07:26 AM) <{POST_SNAPBACK}>

Nice work Don! Glad to hear you got it all fixed up cool.gif

Thanks! I still need to install tupperware. Gotta tell yah I was pretty darn happy when I energized the circuits and worked correctly! WootWoot! Oh Canada!

Submitted by dcarver on Thu, 03/24/2011 - 19:39.
QUOTE (Brodie @ May 18 2009, 02:07 AM) <{POST_SNAPBACK}>

I tend to agree with Slappy, except for the black plastic this looks like a dead ringer for your replacement part.


I know of about 12 companies making the exact same 090 series connectors. Granted, the 13 pin in case is kind of rare. Sometimes a company will offer two different materials that are different colors. IIRC black is typically ABS and the white is typically Nylon.

for future reference, here's the sumitomo catalog for this series. This connector is the last on page 3.

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