Topic: Removing old bullet connectors on harness

[mcswny]

Rather than going through the process of cleaning my old junky 40 year old bullet connects on my harness I was hoping to just replace them with new ones from vintageconnections.com

Is there a good technique or tool for removing them from the exposed copper wires WITHOUT just cutting at the base. In some places if I cut that much off, I'd end up having to solder in some extension and would rather try to keep the lines clean.

Thoughts?

Thanks,
Tim

[flybox1]

go to the KITS section
price is quoted with the crimping tool
http://vintageconnections.com/

Oregon motorcycle parts also sells connections and crimp tools

[mcswny]

go to the KITS section
price is quoted with the crimping tool
http://vintageconnections.com/

Oregon motorcycle parts also sells connections and crimp tools

Does the crimping tool REMOVE connectors as well? I already have a crimping tool as well as hundreds of connectors, just want a clean way of removing the old ones without just cutting them off.

[mcswny]

In theory, I could use a real small flat head screwdriver and small needle nose pliers but was hoping there would be something a bit quicker to remove the old connectors.

[flybox1]

IIWM, id cut them really close and also be sure to get into good clean copper.
re-using the old, corroded, bent/breaking wires would be just asking for trouble in my mind

[madmtnmotors]

I have not had any issues cutting the old ones off. I make sure to cut right at the end of the metal, which means cutting through the insulator on some of the connections. You are only losing about a 1/4" this way, which can be sacrificed on even the shortest of connectors. The shortest ones that come to mind (and the ones that most often need replaced) are the male bullets on yellow leads off the stator, behind the shift cover, underneath the front sprocket cover. I almost always replace these with new vintage connections bullets (get the smaller ones, there are two sizes) and have always been able to crimp new connectors on here (with insulators) without having to remove the stator or the shift cover. Granted, it is tight, but not that difficult, and I have not had any problems with adequate length when complete. That often includes replacing both the male bullet from the stator and the female bullet from the harness. These connectors see especially high current and especially high heat, and are some of the most failure prone connectors on the whole bike.

You only need to strip 1/4" to 5/16" of insulation to use the vintage connections. The total loss of length is only about 1/4" (from trimming off the old connector). The 1/4" to 5/16" that gets stripped back for the new connector is included with the new connector overall, so this is not considered any loss in overall length. Have you got picts of the "short" connections in question?


http://forums.sohc4.net/index.php/topic,137351.msg1549191.html#msg1549191

Here too:

http://forums.sohc4.net/index.php/topic,146874.msg1673371.html#msg1673371

[Don R]

No miracle method as far as I know. You can cut the connector just behind the crimp and save some of the wire. That's what I did on my 750 K0, it worked fine. You can usually tell if a wire end is badly fatigued.

[mcswny]

Thanks for all the responses, I'll just move ahead with cutting right at the base.

The ones I'm really wanting/needing to change are the blue and yellow wires coming off my coils, just seeming corroded and old. Thanks!

[mcswny]

I have not had any issues cutting the old ones off. I make sure to cut right at the end of the metal, which means cutting through the insulator on some of the connections. You are only losing about a 1/4" this way, which can be sacrificed on even the shortest of connectors. The shortest ones that come to mind (and the ones that most often need replaced) are the male bullets on yellow leads off the stator, behind the shift cover, underneath the front sprocket cover. I almost always replace these with new vintage connections bullets (get the smaller ones, there are two sizes) and have always been able to crimp new connectors on here (with insulators) without having to remove the stator or the shift cover. Granted, it is tight, but not that difficult, and I have not had any problems with adequate length when complete. That often includes replacing both the male bullet from the stator and the female bullet from the harness. These connectors see especially high current and especially high heat, and are some of the most failure prone connectors on the whole bike.

You only need to strip 1/4" to 5/16" of insulation to use the vintage connections. The total loss of length is only about 1/4" (from trimming off the old connector). The 1/4" to 5/16" that gets stripped back for the new connector is included with the new connector overall, so this is not considered any loss in overall length. Have you got picts of the "short" connections in question?


http://forums.sohc4.net/index.php/topic,137351.msg1549191.html#msg1549191

Here too:

http://forums.sohc4.net/index.php/topic,146874.msg1673371.html#msg1673371

Quick Question: I hear all different things about the small (3.5mm) vs larger (4.0mm) connectors. Any chance you could quickly explain why one is better than the other in this case?

[madmtnmotors]

I have not had any issues cutting the old ones off. I make sure to cut right at the end of the metal, which means cutting through the insulator on some of the connections. You are only losing about a 1/4" this way, which can be sacrificed on even the shortest of connectors. The shortest ones that come to mind (and the ones that most often need replaced) are the male bullets on yellow leads off the stator, behind the shift cover, underneath the front sprocket cover. I almost always replace these with new vintage connections bullets (get the smaller ones, there are two sizes) and have always been able to crimp new connectors on here (with insulators) without having to remove the stator or the shift cover. Granted, it is tight, but not that difficult, and I have not had any problems with adequate length when complete. That often includes replacing both the male bullet from the stator and the female bullet from the harness. These connectors see especially high current and especially high heat, and are some of the most failure prone connectors on the whole bike.

You only need to strip 1/4" to 5/16" of insulation to use the vintage connections. The total loss of length is only about 1/4" (from trimming off the old connector). The 1/4" to 5/16" that gets stripped back for the new connector is included with the new connector overall, so this is not considered any loss in overall length. Have you got picts of the "short" connections in question?


http://forums.sohc4.net/index.php/topic,137351.msg1549191.html#msg1549191

Here too:

http://forums.sohc4.net/index.php/topic,146874.msg1673371.html#msg1673371

Quick Question: I hear all different things about the small (3.5mm) vs larger (4.0mm) connectors. Any chance you could quickly explain why one is better than the other in this case?

Because the 3.5mm bullets are the size of the bullet connectors that Honda used from the factory on these old bikes.

I highly recommend getting the crimp tool to go with the connectors:

http://forums.sohc4.net/index.php/topic,146874.msg1673371.html#msg1673371

and I would also recommend looking at the bullet connectors from the stator that I described above.

[mcswny]

I have not had any issues cutting the old ones off. I make sure to cut right at the end of the metal, which means cutting through the insulator on some of the connections. You are only losing about a 1/4" this way, which can be sacrificed on even the shortest of connectors. The shortest ones that come to mind (and the ones that most often need replaced) are the male bullets on yellow leads off the stator, behind the shift cover, underneath the front sprocket cover. I almost always replace these with new vintage connections bullets (get the smaller ones, there are two sizes) and have always been able to crimp new connectors on here (with insulators) without having to remove the stator or the shift cover. Granted, it is tight, but not that difficult, and I have not had any problems with adequate length when complete. That often includes replacing both the male bullet from the stator and the female bullet from the harness. These connectors see especially high current and especially high heat, and are some of the most failure prone connectors on the whole bike.

You only need to strip 1/4" to 5/16" of insulation to use the vintage connections. The total loss of length is only about 1/4" (from trimming off the old connector). The 1/4" to 5/16" that gets stripped back for the new connector is included with the new connector overall, so this is not considered any loss in overall length. Have you got picts of the "short" connections in question?


http://forums.sohc4.net/index.php/topic,137351.msg1549191.html#msg1549191

Here too:

http://forums.sohc4.net/index.php/topic,146874.msg1673371.html#msg1673371

Quick Question: I hear all different things about the small (3.5mm) vs larger (4.0mm) connectors. Any chance you could quickly explain why one is better than the other in this case?

Because the 3.5mm bullets are the size of the bullet connectors that Honda used from the factory on these old bikes.

I highly recommend getting the crimp tool to go with the connectors:

http://forums.sohc4.net/index.php/topic,146874.msg1673371.html#msg1673371

and I would also recommend looking at the bullet connectors from the stator that I described above.

Great! thanks. FWIW I have a butt load of 3.5mm and 4.0mm connectors (the 4.0 for my 1997 XR600r).

I also have a really good crimping tool.

I will definitely take a look at the stator connectors as well, thanks!

[Jerry Rxman Griffin aka MuthaF'er]

I think the 3 yellow stator wire's bullets tend to be the worst offenders due to the current and heat generated. PLUS they are the ONLY ones I had trouble with due to length. Once you replace a few and see how much 'snappier' they are you may just go nuts and use up a buncha connectors  which is a good idea on most of these old harnesses. Don't forget the new shields and dielectric grease to protect them from the elements and further corrosion.

[mcswny]

I think the 3 yellow stator wire's bullets tend to be the worst offenders due to the current and heat generated. PLUS they are the ONLY ones I had trouble with due to length. Once you replace a few and see how much 'snappier' they are you may just go nuts and use up a buncha connectors  which is a good idea on most of these old harnesses. Don't forget the new shields and dielectric grease to protect them from the elements and further corrosion.

Ha, if I know my self, I'll sit down to replace 6 connectors. And then 2 hours and a six pack later, everything will be replaced.

[madmtnmotors]

I think the 3 yellow stator wire's bullets tend to be the worst offenders due to the current and heat generated. PLUS they are the ONLY ones I had trouble with due to length. Once you replace a few and see how much 'snappier' they are you may just go nuts and use up a buncha connectors  which is a good idea on most of these old harnesses. Don't forget the new shields and dielectric grease to protect them from the elements and further corrosion.

Ha, if I know my self, I'll sit down to replace 6 connectors. And then 2 hours and a six pack later, everything will be replaced.

Time well spent. Eliminate those electrical gremlins before the procreate! 

[mcswny]

I think the 3 yellow stator wire's bullets tend to be the worst offenders due to the current and heat generated. PLUS they are the ONLY ones I had trouble with due to length. Once you replace a few and see how much 'snappier' they are you may just go nuts and use up a buncha connectors  which is a good idea on most of these old harnesses. Don't forget the new shields and dielectric grease to protect them from the elements and further corrosion.

Ha, if I know my self, I'll sit down to replace 6 connectors. And then 2 hours and a six pack later, everything will be replaced.

Time well spent. Eliminate those electrical gremlins before the procreate! 

I'm on it! Gettin her ready for a 2,000 mile trip from Brooklyn to Nova Scotia and back in 2 months.