Author Topic: Electrical - Harness Corrosion  (Read 6475 times)

0 Members and 1 Guest are viewing this topic.

Offline nccb

  • Expert
  • ****
  • Posts: 1,145
  • 1974 CB750 Four
Electrical - Harness Corrosion
« on: September 23, 2012, 03:16:24 PM »
Just wondering if anyone can help me with cleaning my electrical harnesses.  I had a post about my headlight not working and cleaned out the harness with QD to get it to work again.  It went off again yesterday, so I took it off and recleaned with QD and again it works.  Is there anything else I should be placing on the connections to stop it from corroding?  Is this where I should be using Dialectric grease to stop it from corroding?

Offline madmtnmotors

  • When did I get to be a
  • Really Old Timer ...
  • *******
  • Posts: 6,090
  • Sunny Central Florida
Re: Electrical - Harness Corrosion
« Reply #1 on: September 23, 2012, 06:19:25 PM »
Just rehabilitated the entire harness of a CB750. Took about two weeks working through the weekends and almost every evening. Manually cleaned EVERY connector:


Some of the worst connectors looked like this:


Vintage connections makes a tool that helps getting connectors apart:


Keep a notepad handy for those multi connector blocks:


YUCK!


A Dremel with a wire wheel is a POWERFUL tool!


Steel wool does a good job of cleaning rattlecan overspray off the wire insulation that some goob PO got all over EVERYTHING:


Nice!


Don't forget to bend the retaining tabs back into place:


Viola'!


I then gave all the newly cleaned contacts a shot of tuner cleaner/lubricant: http://www.radioshack.com/search/index.jsp?kwCatId=&kw=tuner%20cleaner&origkw=tuner+cleaner&sr=1

Purple Power (or "That Purple Stuff") does a bang up job of removing paint from plastic without damaging the plastic. Use gloves when removing parts from solution and wash parts thoroughly. It does not appear to harm plastic, but it's a little rough on the skin.

The female connectors (both bullet and spade) are more difficult to clean (insert favorite chauvanist remark here) but the same principles apply. For the female spades I used the dremel w/wire wheel for the outer part of the connector (just to remove any oxidation that might promote more oxidation) and then used a narrow strip of tin with a narrow strip of 320grit sandpaper folded over it to clean the inside of the spade connection. A pinch with the pliers prior to reassembly to assure a good, tight connection finishes the spade connectors (don't forget the locking tab on these too). The male bullets clean up the same as the male spades, while the female bullets require either a small diameter wire bottle brush (.177 cal bore brush is a popular choice) or an assortment of small diameter diamond stones for the Dremel (my choice). Again, a little pinch with the pliers to assure a tight connection, a little shot of tuner cleaner/lubricant, and, if you did everything right, you're good for another 30 years.

While I was at it I pulled apart the switches and cleaned them too. Here is the rear brake switch at the rear brake foot pedal:

Before:


After:


If you don't want to tackle the whole harness at once (quite daunting) then start with the primary circuits starting at the fuse box. Clean all the fuse holder connectors and harness connections to the fuse box. Then clean all the problem connectors in the headlight bucket (the headlight circuit in your case). You might want to inspect/clean the charging system connections too for more reliable performance. I did this more targeted approach (as opposed to the whole harness) with my daily driver a couple years ago after it started blowing the main fuse. Still trouble free after this form of maintenance. This process WILL try your patience.

Oh yeah, DISCONNECT THE BATTERY!
« Last Edit: September 24, 2012, 04:44:07 AM by madmtnmotors »
TAMTF...


Wilbur



Projects:
"Evolution": http://forums.sohc4.net/index.php?topic=100352.0
"P.O. Debacle": http://forums.sohc4.net/index.php/topic,126692.msg1441661.html#msg1441661
F2/F3 O-rings: http://forums.sohc4.net/index.php?topic=113672.msg1300721#msg1300721
Cam Tower Studs: https://www.mcmaster.com/#93210a017/=t19sgp
Clean up that nasty harness: http://forums.sohc4.net/index.php?topic=137351.msg1549191#msg1549191
http://forums.sohc4.net/index.php/topic,148188.msg1688494.html#msg1688494
http://forums.sohc4.net/index.php/topic,139544.msg1579364.html#msg1579364
                                          
Charging system diagnosis: http://forums.sohc4.net/index.php?topic=1012.msg8345#msg8345
Get the manuals: http://manuals.sohc4.net/cb750k/
The Dragon: http://forums.sohc4.net/index.php?topic=45183.msg1571675#msg1571675
Headlight Switch: http://forums.sohc4.net/index.php?topic=113986.msg1283236#msg1283236
Branden's leak free top end thread: http://forums.sohc4.net/index.php?topic=107040.0
Engine Lifting Made Easy: http://forums.sohc4.net/index.php/topic,58210.msg1684742.html#msg1684742
                                      http://forums.sohc4.net/index.php/topic,100352.msg1675840.html#msg1675840
Static and Dynamic Timing: http://www.hondachopper.com/garage/carb_info/timing/timing1.html
Airbox Gasket Replacement: http://forums.sohc4.net/index.php/topic,114485.msg1290000.html#msg1290000
"Café" : http://forums.sohc4.net/index.php/topic,84697.msg953814.html#msg953814
PD Carb Choke Linkage: http://forums.sohc4.net/index.php/topic,100352.msg1669248.html#msg1669248
                                    http://forums.sohc4.net/index.php/topic,110931.msg1248354.html#msg1248354
                                    http://forums.sohc4.net/index.php/topic,48858.msg515204.html#msg515204
Follow up on your damn posts: http://forums.sohc4.net/index.php/topic,144305.msg1791605.html#msg1791605
Taiwanese Cam Chain Tensioners:  http://forums.sohc4.net/index.php/topic,155043.msg1774841.html#msg1774841
Gumtwo Seat Cover: http://forums.sohc4.net/index.php/topic,164440.msg1897366.html#msg1897366
Primary Drive: http://forums.sohc4.net/index.php/topic,166063.msg1919278.html#msg1919278
Tank Latch: http://forums.sohc4.net/index.php/topic,165975.msg1919495.html#msg1919495
Shorten your forks: http://vintage-and-classic-honda-s.456789.n3.nabble.com/How-to-shorten-forks-td4042465.html DO NOT CUT THE SPRINGS!
Clutch How To: http://vintage-and-classic-honda-s.456789.n3.nabble.com/How-to-change-and-adjust-a-clutch-SOHC-td4040391.html
Late model K7/K8/F2/F3 front sprocket cover removal: http://forums.sohc4.net/index.php/topic,178428.msg2072279.html#msg2072279
630 to 530 conversion: http://forums.sohc4.net/index.php/topic,180710.msg2094423.html#msg2094423

Sent from my Tandy TRS-80!

Offline Jerry Rxman Griffin aka MuthaF'er

  • This MuthaF'er is getting to be a
  • Really Old Timer ...
  • *******
  • Posts: 14,902
  • Bought her new 4/75
Re: Electrical - Harness Corrosion
« Reply #2 on: September 23, 2012, 06:47:37 PM »
Clean then apply dielectric grease liberally. Be sure that the connectors snap together with a noticeable snap feeling for good contact.
Vintageconnections.com has all the connectors and crimping tool should you wish to replace any connectors. The tool is invaluable!

If you want to make a homemade tool to release the spades in a multi-connector just take a large paperclip and hammer one end flat.
« Last Edit: September 23, 2012, 06:51:25 PM by Jerry Rxman Griffin »
As of today 3/13/2012 my original owner 75 CB750F has made it through 3 wives, er EX-wives. Free at last.  ;-)

Offline jason41987

  • Hot Shot
  • ***
  • Posts: 520
Re: Electrical - Harness Corrosion
« Reply #3 on: September 23, 2012, 07:11:22 PM »
ever thought about using your old wiring harness as a template to fabricate a new one?... im sure after 40 years even the protected wiring has become brittle and fragile over the years, increasing resistance or losing continuity all together

Offline HondaMan

  • Someone took this pic of me before I became a
  • Really Old Timer ...
  • *******
  • Posts: 13,793
  • ...not my choice, I was nicknamed...
    • Getting 'em Back on the Road
Re: Electrical - Harness Corrosion
« Reply #4 on: September 23, 2012, 07:43:41 PM »
Just rehabilitated the entire harness of a CB750. Took about two weeks working through the weekends and almost every evening. Manually cleaned EVERY connector:


Wow, that's dedication and perseverance! I often cut off the connectors and install new ones.

You still have a working Trash-80? I'm impressed. :)
See SOHC4shop@gmail.com for info about the gadgets I make for these bikes.

The demons are repulsed when a man does good. Use that.
Blood is thicker than water, but motor oil is thicker yet...so, don't mess with my SOHC4, or I might have to hurt you.
Hondaman's creed: "Bikers are family. Treat them accordingly."

Link to Hondaman Ignition: http://forums.sohc4.net/index.php?topic=67543.0

Link to My CB750 Book: https://www.lulu.com/search?adult_audience_rating=00&page=1&pageSize=10&q=my+cb750+book

Link to website: www.SOHC4shop.com

Offline madmtnmotors

  • When did I get to be a
  • Really Old Timer ...
  • *******
  • Posts: 6,090
  • Sunny Central Florida
Re: Electrical - Harness Corrosion
« Reply #5 on: September 23, 2012, 08:24:29 PM »
Just rehabilitated the entire harness of a CB750. Took about two weeks working through the weekends and almost every evening. Manually cleaned EVERY connector:


Wow, that's dedication and perseverance! I often cut off the connectors and install new ones.

A couple were beyond saving, I did have to replace a couple of individual brass connectors and a couple of the plastic multi-connector bodies (just the plastic part that had melted from over amping at the corroded connectors). Even had to replace about 8" of a ground wire that got so hot it shed it's insulation! I am definitely determined to keep costs in check without sacrificing safety, functionality, or reliability.


You still have a working Trash-80? I'm impressed. :)

LOL, gave up the TRS-80 long ago, but I do have a buddy with a working version of the handheld TRS-80.
TAMTF...


Wilbur



Projects:
"Evolution": http://forums.sohc4.net/index.php?topic=100352.0
"P.O. Debacle": http://forums.sohc4.net/index.php/topic,126692.msg1441661.html#msg1441661
F2/F3 O-rings: http://forums.sohc4.net/index.php?topic=113672.msg1300721#msg1300721
Cam Tower Studs: https://www.mcmaster.com/#93210a017/=t19sgp
Clean up that nasty harness: http://forums.sohc4.net/index.php?topic=137351.msg1549191#msg1549191
http://forums.sohc4.net/index.php/topic,148188.msg1688494.html#msg1688494
http://forums.sohc4.net/index.php/topic,139544.msg1579364.html#msg1579364
                                          
Charging system diagnosis: http://forums.sohc4.net/index.php?topic=1012.msg8345#msg8345
Get the manuals: http://manuals.sohc4.net/cb750k/
The Dragon: http://forums.sohc4.net/index.php?topic=45183.msg1571675#msg1571675
Headlight Switch: http://forums.sohc4.net/index.php?topic=113986.msg1283236#msg1283236
Branden's leak free top end thread: http://forums.sohc4.net/index.php?topic=107040.0
Engine Lifting Made Easy: http://forums.sohc4.net/index.php/topic,58210.msg1684742.html#msg1684742
                                      http://forums.sohc4.net/index.php/topic,100352.msg1675840.html#msg1675840
Static and Dynamic Timing: http://www.hondachopper.com/garage/carb_info/timing/timing1.html
Airbox Gasket Replacement: http://forums.sohc4.net/index.php/topic,114485.msg1290000.html#msg1290000
"Café" : http://forums.sohc4.net/index.php/topic,84697.msg953814.html#msg953814
PD Carb Choke Linkage: http://forums.sohc4.net/index.php/topic,100352.msg1669248.html#msg1669248
                                    http://forums.sohc4.net/index.php/topic,110931.msg1248354.html#msg1248354
                                    http://forums.sohc4.net/index.php/topic,48858.msg515204.html#msg515204
Follow up on your damn posts: http://forums.sohc4.net/index.php/topic,144305.msg1791605.html#msg1791605
Taiwanese Cam Chain Tensioners:  http://forums.sohc4.net/index.php/topic,155043.msg1774841.html#msg1774841
Gumtwo Seat Cover: http://forums.sohc4.net/index.php/topic,164440.msg1897366.html#msg1897366
Primary Drive: http://forums.sohc4.net/index.php/topic,166063.msg1919278.html#msg1919278
Tank Latch: http://forums.sohc4.net/index.php/topic,165975.msg1919495.html#msg1919495
Shorten your forks: http://vintage-and-classic-honda-s.456789.n3.nabble.com/How-to-shorten-forks-td4042465.html DO NOT CUT THE SPRINGS!
Clutch How To: http://vintage-and-classic-honda-s.456789.n3.nabble.com/How-to-change-and-adjust-a-clutch-SOHC-td4040391.html
Late model K7/K8/F2/F3 front sprocket cover removal: http://forums.sohc4.net/index.php/topic,178428.msg2072279.html#msg2072279
630 to 530 conversion: http://forums.sohc4.net/index.php/topic,180710.msg2094423.html#msg2094423

Sent from my Tandy TRS-80!

Offline Spanner 1

  • Old Timer
  • ******
  • Posts: 4,092
  • CB 750 K0 ( always thought it was a K1!) + CB750K8
Re: Electrical - Harness Corrosion
« Reply #6 on: September 23, 2012, 08:59:51 PM »
Outstanding post and work Mad....... imagine how many SOHC bikes are running around with the 'before' pictures being the state of their electrical..... can't say how important this clean-up is to achieve a reliable bike... IMO  ;)
If your sure it's a carb problem; it's ignition,
If your sure it's an ignition problem; it's carbs....

Offline seanbarney41

  • not really that much younger than an
  • Really Old Timer ...
  • *******
  • Posts: 10,805
Re: Electrical - Harness Corrosion
« Reply #7 on: September 24, 2012, 05:46:44 PM »
nice thread...now let's see if my attention span will ever be capable of performing this work :)
If it works good, it looks good...

Offline nccb

  • Expert
  • ****
  • Posts: 1,145
  • 1974 CB750 Four
Re: Electrical - Harness Corrosion
« Reply #8 on: September 24, 2012, 05:56:13 PM »
wow. nice madmtnmotors.  so even if there is a little bit of oxidation left that will cause it to keep corroding faster?  Most of mine look decent, nothing like your clean ones, but the problem male connector on the fuse harness does look like how yours did; and it runs to the headlight.

Offline madmtnmotors

  • When did I get to be a
  • Really Old Timer ...
  • *******
  • Posts: 6,090
  • Sunny Central Florida
Re: Electrical - Harness Corrosion
« Reply #9 on: September 24, 2012, 06:06:33 PM »
The primary focus should be the contact points of the connector itself. If the contact surface is clean then you should be good. I may go a little overboard (anal?  :o ) but two-wheeled transportation is hazardous enough without an electrical failure rearing its ugly head while I'm trying to power away from or around a hazard (or merge on/off the highway). Definitely clean up the fuse panel connectors, including the tabs that hold the fuses. The charging system connectors are high amp circuits too so you might give those connectors a once-over as well. The female half of the connector is the most difficult to clean well.
TAMTF...


Wilbur



Projects:
"Evolution": http://forums.sohc4.net/index.php?topic=100352.0
"P.O. Debacle": http://forums.sohc4.net/index.php/topic,126692.msg1441661.html#msg1441661
F2/F3 O-rings: http://forums.sohc4.net/index.php?topic=113672.msg1300721#msg1300721
Cam Tower Studs: https://www.mcmaster.com/#93210a017/=t19sgp
Clean up that nasty harness: http://forums.sohc4.net/index.php?topic=137351.msg1549191#msg1549191
http://forums.sohc4.net/index.php/topic,148188.msg1688494.html#msg1688494
http://forums.sohc4.net/index.php/topic,139544.msg1579364.html#msg1579364
                                          
Charging system diagnosis: http://forums.sohc4.net/index.php?topic=1012.msg8345#msg8345
Get the manuals: http://manuals.sohc4.net/cb750k/
The Dragon: http://forums.sohc4.net/index.php?topic=45183.msg1571675#msg1571675
Headlight Switch: http://forums.sohc4.net/index.php?topic=113986.msg1283236#msg1283236
Branden's leak free top end thread: http://forums.sohc4.net/index.php?topic=107040.0
Engine Lifting Made Easy: http://forums.sohc4.net/index.php/topic,58210.msg1684742.html#msg1684742
                                      http://forums.sohc4.net/index.php/topic,100352.msg1675840.html#msg1675840
Static and Dynamic Timing: http://www.hondachopper.com/garage/carb_info/timing/timing1.html
Airbox Gasket Replacement: http://forums.sohc4.net/index.php/topic,114485.msg1290000.html#msg1290000
"Café" : http://forums.sohc4.net/index.php/topic,84697.msg953814.html#msg953814
PD Carb Choke Linkage: http://forums.sohc4.net/index.php/topic,100352.msg1669248.html#msg1669248
                                    http://forums.sohc4.net/index.php/topic,110931.msg1248354.html#msg1248354
                                    http://forums.sohc4.net/index.php/topic,48858.msg515204.html#msg515204
Follow up on your damn posts: http://forums.sohc4.net/index.php/topic,144305.msg1791605.html#msg1791605
Taiwanese Cam Chain Tensioners:  http://forums.sohc4.net/index.php/topic,155043.msg1774841.html#msg1774841
Gumtwo Seat Cover: http://forums.sohc4.net/index.php/topic,164440.msg1897366.html#msg1897366
Primary Drive: http://forums.sohc4.net/index.php/topic,166063.msg1919278.html#msg1919278
Tank Latch: http://forums.sohc4.net/index.php/topic,165975.msg1919495.html#msg1919495
Shorten your forks: http://vintage-and-classic-honda-s.456789.n3.nabble.com/How-to-shorten-forks-td4042465.html DO NOT CUT THE SPRINGS!
Clutch How To: http://vintage-and-classic-honda-s.456789.n3.nabble.com/How-to-change-and-adjust-a-clutch-SOHC-td4040391.html
Late model K7/K8/F2/F3 front sprocket cover removal: http://forums.sohc4.net/index.php/topic,178428.msg2072279.html#msg2072279
630 to 530 conversion: http://forums.sohc4.net/index.php/topic,180710.msg2094423.html#msg2094423

Sent from my Tandy TRS-80!

Offline nitroeagle

  • Full Member
  • *
  • Posts: 72
Re: Electrical - Harness Corrosion
« Reply #10 on: September 24, 2012, 08:02:17 PM »
You can also use some valve lapping compound. Mix with water to make a paste. Put in on the terminals & work them in & out enough to get rid of the corrosion(not too much). Then rinse off.

Offline Eddie

  • Enthusiast
  • **
  • Posts: 237
Re: Electrical - Harness Corrosion
« Reply #11 on: September 25, 2012, 05:51:34 AM »
This is what i did on my bike.  I bought cotton pipe cleaners and Tarnex. Cleaned all connectors, rinsed them right away with denatured alcohol, blew dry with compressor then a good healthy spray of DeOxit.  I try not to use anything too course and scrape up the terminals as any mild scratches will cause problems on a high current contact. Mine were not as bad as Madmtnmotors, if they were the dremel looks to be the tool of choice.

Offline Spanner 1

  • Old Timer
  • ******
  • Posts: 4,092
  • CB 750 K0 ( always thought it was a K1!) + CB750K8
Re: Electrical - Harness Corrosion
« Reply #12 on: September 25, 2012, 11:04:00 AM »
OP.... have you still got the original fuse block ?... have you shone-up the fuse clips and squeezed them together ( carefully ) so as they grip each fuse tightly ? Do they have the correct length fuses in the clips ? You already report that the fuse harness connector needs attention....
If your sure it's a carb problem; it's ignition,
If your sure it's an ignition problem; it's carbs....

Offline nccb

  • Expert
  • ****
  • Posts: 1,145
  • 1974 CB750 Four
Re: Electrical - Harness Corrosion
« Reply #13 on: September 25, 2012, 03:39:11 PM »
OP.... have you still got the original fuse block ?... have you shone-up the fuse clips and squeezed them together ( carefully ) so as they grip each fuse tightly ? Do they have the correct length fuses in the clips ? You already report that the fuse harness connector needs attention....

I do still have the original fuse block but haven't shone-up the fuse clips.  To me that look pretty clean but after seeing how shiny that copper/brass gets im not so sure anymore.  The fuses are all the correct length and they fit pretty tightly.  The only issue I have with it is my headlight has started to intermittently stop and one connector does have heavier corrosion, which is also going to the 7amp fuse.  I do need to give it a good cleaning because the QD doesn't seem to dissolve all the corrosion like I was hoping so I will probably try madmtnmotors method (although idk if I can go through all the steps 8))

Offline mono

  • Definitely no
  • Expert
  • ****
  • Posts: 1,271
  • 1975 Honda CB550, 1978 CB750K (in progress)
Re: Electrical - Harness Corrosion
« Reply #14 on: September 25, 2012, 04:24:38 PM »
nice work, mad - i did the same thing on my 550 harness over the winter.  took hours and hours, but it was worth it!

so yeah, do what mad did and also use that dielectric grease to keep the connection from corroding again.  cleaning wiring harnesses builds character!  hahaha

Offline becken

  • Hot Shot
  • ***
  • Posts: 270
Re: Electrical - Harness Corrosion
« Reply #15 on: September 26, 2012, 09:05:21 AM »
http://www.corrosionx.com/

I found out about this company from an aircraft technician. Corrosion protection is even more important in aircraft as you can't pull over to the side of road.
1976 CB550F bought new
1981 CM400A wife bought new
2004 GL1800

Offline Rgconner

  • Hot Shot
  • ***
  • Posts: 674
Re: Electrical - Harness Corrosion
« Reply #16 on: September 26, 2012, 09:29:58 AM »
Ditto on Corrosion X or similar products available at Fry's, Greybar  or your local electrical supply house.

And of course probably your nearest public airport has a parts shop nearby, might want to try them.

The stuff I got it was spray and wipe, all the corrosion came off and left a nice coating of inhibitor.

Another trick: turn off the lights, turn on the headlight. Start flexing wires and if the headlight flickers/brightens/dims, you have a problem. Surprising this tends to work even if the wiring in question is not for the headlight, the change in overall resistance makes the light flicker slightly.

1975 CB550K aka "Grease Monkey"


Offline becken

  • Hot Shot
  • ***
  • Posts: 270
Re: Electrical - Harness Corrosion
« Reply #18 on: September 26, 2012, 03:25:52 PM »
CorrosionX makes products for many different uses from skate boards and fishing reels to heavy duty spray on. I sprayed the bottoms of my car and truck doors in the fall and it was still there come spring. Pick the right product and you'll be very satisfied.

Their RejeX is absolutely awesome.
1976 CB550F bought new
1981 CM400A wife bought new
2004 GL1800