Author Topic: Wiring Harness Connectors  (Read 5976 times)

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Offline Kustomizer

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Wiring Harness Connectors
« on: May 27, 2015, 04:48:12 PM »
I've replaced the switches on my cb750 Cafe project and need to shorten the wires, but can't find the smaller male bullet connectors.  I can find the normal, larger ones that all the auto parts stores carry, but these are smaller.  Can someone tell me where to buy the smaller connectors.

Offline flybox1

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Re: Wiring Harness Connectors
« Reply #1 on: May 27, 2015, 04:53:19 PM »
vintageconnections.com
oregonmotorcycleparts.com
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Offline Kustomizer

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Re: Wiring Harness Connectors
« Reply #2 on: May 27, 2015, 05:17:15 PM »
Thanks for the info.  One question, would the bullet connectors on our honda's be the 4mm or, if not, what size should I be looking for?

Offline calj737

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Re: Wiring Harness Connectors
« Reply #3 on: May 27, 2015, 05:26:11 PM »
3.5mm
'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
'73 500 Build http://forums.sohc4.net/index.php?topic=132935.0

"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline Kustomizer

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Re: Wiring Harness Connectors
« Reply #4 on: May 27, 2015, 05:34:48 PM »

Offline madmtnmotors

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Re: Wiring Harness Connectors
« Reply #5 on: May 27, 2015, 06:38:28 PM »
I highly recommend the proper crimp tool. Here is a copy of my post from another thread, ironically titled "Electrical Connectors":



Strip it. I usually strip about a 1/4" to 5/16". Three-eights is a bit much and not necessary:






Don't forget the insulator! (ask me how I know):




I finally figured out (after about three tries) that it's easier to load the connector in the crimp tool first. Note the stepped jaw. The trailing end has a higher relief so as not to over crimp the insulation:




Ratchet down on it just enough to hold it:






You only need about a 1/4" of insulation extended into the connector. Too much and you get into the part of the crimp that should be catching wire only. The jaws are pretty wide and hard to see inside, so I use my thumbnail as a guide when inserting the wire:






Crimp it!:




Voila' (as opposed to "Viola" which everyone knows is a musical instrument):




And finally, the insulator:




Procedure is the same for other types of connectors, just be sure to use the right insulator. Here we have the insulator for the female bullet:




Load the tool:




Crimp it... crimp it real good... and voila'! (as opposed to "viola" which everyone knows is a musical instrument):




Slide the insulator into place:




Dang! This is how they must of looked when the bike was new!:






Give the wire a tug when you're done. Occasionally I will get a loose crimp, but most of the time it is a result of smaller gauge wire. In those cases I will strip 1/2" of insulation and double the wire back on itself to mimic a heavier gauge wire. These are my go-to connectors for all things automotive.  8)
« Last Edit: May 28, 2015, 04:51:54 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 calj737

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Re: Wiring Harness Connectors
« Reply #6 on: May 27, 2015, 06:46:57 PM »
That's a nice step by step on crimping, Wilnur. But, a V-I-o-l-a is a musical instrument, while V-o-i-l-à is an oft used French word for "presto!"  Just an FYI
'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
'73 500 Build http://forums.sohc4.net/index.php?topic=132935.0

"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline wowbagger

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Re: Wiring Harness Connectors
« Reply #7 on: May 27, 2015, 06:47:36 PM »
+1 on buying the crimp tool.

The only step I'd add is to dab a bit of solder onto the crimped connector to ensure it lasts for another 40+ years.

Offline HondaMan

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Re: Wiring Harness Connectors
« Reply #8 on: May 27, 2015, 09:48:14 PM »
+1 on buying the crimp tool.

The only step I'd add is to dab a bit of solder onto the crimped connector to ensure it lasts for another 40+ years.
Here's something you may not know about the crimper from Vintageconnections.com: it makes a gas-tight crimp if you pick the right size slot and wire. This will NEVER corrode, because oxygen can't get inside the metal sealed joint.

The OEM bullets before 1973 in these bikes were soldered in, then stress-relieved with a non-gastight crimp. The solder saved them, but in the 1974 versions the gastight crimps took over (cheaper to make) instead.

;)
See SOHC4shop@gmail.com for info about the gadgets I make for these bikes.

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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.
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Offline madmtnmotors

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Re: Wiring Harness Connectors
« Reply #9 on: May 28, 2015, 04:06:01 AM »
That's a nice step by step on crimping, Wilnur. But, a V-I-o-l-a is a musical instrument, while V-o-i-l-à is an oft used French word for "presto!"  Just an FYI

LOL. My spell checker is broke!  :o

and I usually spell Wilbur with a "b"....  ;)
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 calj737

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Re: Wiring Harness Connectors
« Reply #10 on: May 28, 2015, 04:07:38 AM »
That was to see if you were paying attention  ;D I just couldn't tell if you thought this should be another anecdote from band camp?  :)
'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
'73 500 Build http://forums.sohc4.net/index.php?topic=132935.0

"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline wowbagger

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Re: Wiring Harness Connectors
« Reply #11 on: May 28, 2015, 04:16:33 AM »
HondaMan, thanks for the schooling.  I had no idea hat crimp was gas tight. I'll probably still keep soldering my joints though just to protect against any poor crimps on my part. It takes more time but it can't hurt (I don't think).

Offline Vinhead1957

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Re: Wiring Harness Connectors
« Reply #12 on: May 28, 2015, 04:52:11 AM »
Never solder crimps.  It reduces the flexibility of the stranded wire and it can break at the crimp.    Nothing is better than a pure crimp like is above.

Offline madmtnmotors

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Re: Wiring Harness Connectors
« Reply #13 on: May 28, 2015, 04:56:31 AM »
+1 on buying the crimp tool.

The only step I'd add is to dab a bit of solder onto the crimped connector to ensure it lasts for another 40+ years.
Here's something you may not know about the crimper from Vintageconnections.com: it makes a gas-tight crimp if you pick the right size slot and wire. This will NEVER corrode, because oxygen can't get inside the metal sealed joint.

The OEM bullets before 1973 in these bikes were soldered in, then stress-relieved with a non-gastight crimp. The solder saved them, but in the 1974 versions the gastight crimps took over (cheaper to make) instead.

;)

Very interesting indeed. I'll never go back to "dime store" crimp connectors!
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 mcswny

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Re: Wiring Harness Connectors
« Reply #14 on: May 28, 2015, 06:48:16 AM »
Wilbur for the win.
1972 CB750 K2
1997 XR600r (street legal)
1975 XL250
198 XR80

Offline MickB

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Re: Wiring Harness Connectors
« Reply #15 on: May 28, 2015, 04:13:54 PM »
Viola voilà, the first has a more musical tone when spoken. Potato potarto spud. I could spit chips.

Offline Kustomizer

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Re: Wiring Harness Connectors
« Reply #16 on: May 28, 2015, 08:48:37 PM »
Awesome tutorial, I'll get a crip tool also, thanks!

Offline heyitsrama

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Re: Wiring Harness Connectors
« Reply #17 on: May 29, 2015, 11:45:02 PM »
the owner of vintage connections is in the same town as me, but his website does not allow for pickup of items. :( so sad at least he refunds me on some shipping.... i mean go figure its literally down the street. Except the last time I ordered, they took the package from the post office, shipped it to Oakland, then back to Fremont.  :o :o Quality Stuff from vintageconnections
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72' cb500
I can't believe it's not butter.