Author Topic: Alternative wiring connectors for multi junctions  (Read 448 times)

Offline 71 V12

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Alternative wiring connectors for multi junctions
« on: January 07, 2019, 06:14:43 PM »
Another electrical question from me for you experts. I find the single bullet connectors are quite good having a positive click and secure latch to them when pushed together.

However I find the multi bullet connectors like the black 5 way and 4 ways for the indicators quite hopeless. They don't seem to give a secure firm connection at all. Last thing you want is unreliable electrics at any time.

I could cut the connector off the wires, tin the wires and use a standard block connector, but I am sure there must be a better solution, any ideas?

Many thanks,

Kevin

Offline Bryanj

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Re: Alternative wiring connectors for multi junctions
« Reply #1 on: January 07, 2019, 07:04:55 PM »
If you mean the multi female bullet and single male connectors you can gently nip up the female part with needle nose pliers to make a tighter fit.
New female connectors are available but you may need to change the males as well as there are 2, very different, sizes.
Those "chocolate block" connectors dont connect to each other unless you fit link wires.

Offline BigAl

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Re: Alternative wiring connectors for multi junctions
« Reply #2 on: January 07, 2019, 08:02:19 PM »
The best solution is to replace the round pin connectors with 6.3mm spade connectors (as image, Yamaha RD250 alternator conversion)
Just curious, which Honda are you working on?
Current bikes:-
Honda CB750 K4 (1974) USA
Honda XL500S (1980) UK
Honda CD175 sloper (1968) UK
Honda CB1100A (2013) UK
www.alans-electrics.co.uk

Offline 71 V12

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Re: Alternative wiring connectors for multi junctions
« Reply #3 on: January 07, 2019, 08:39:27 PM »
Hi Al.
CB750K4  :)

Offline 71 V12

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Re: Alternative wiring connectors for multi junctions
« Reply #4 on: January 07, 2019, 09:44:44 PM »
Hi Al,
I think I see what you mean now. Do you double/ triple crimp the wires to the 6.3mm terminals?

Offline BigAl

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Re: Alternative wiring connectors for multi junctions
« Reply #5 on: January 08, 2019, 04:51:03 PM »
HI Kevin,

I misunderstood the question, I thought someone had replaced the 3.5mm multi socket connectors with mini-block connectors.. 'black 5-way and 4-ways'?
As you mentioned the OE 3.5mm 4-way socket connectors are a bit 'soft' and are better replaced with 2-way or 3-way 3.9mm sockets (see image)
Some doubling-up of wiring will be required to form the additional sockets.

PS your other post 'MOT, park/city light in head light requirement' I've had 9 MOT's on my CB750 K4 with no problems...no one mentioned it.

Alan
Current bikes:-
Honda CB750 K4 (1974) USA
Honda XL500S (1980) UK
Honda CD175 sloper (1968) UK
Honda CB1100A (2013) UK
www.alans-electrics.co.uk

Offline 71 V12

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Re: Alternative wiring connectors for multi junctions
« Reply #6 on: January 08, 2019, 07:18:12 PM »
Hello Alan,

Thank you for the response on both topics. I was concerned about lack of a sidelight but with the feedback I have received now confident the US spec lighting will not be a problem.

With regard to the connectors and after some discussion with an auto electrician I am going for a 2.8mm mini connector from vehicle wiring products. I think this system will give secure connections and therefore good reliability.

I will post some pics when completed.

Offline Bryanj

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Re: Alternative wiring connectors for multi junctions
« Reply #7 on: January 09, 2019, 12:52:37 AM »
They are good connecter but you need small, special crimpers to do the terminals. The "normal" crimpers for blue and red ones dont work you need ones that "fold" the ears in. Give me a bit of time and i will find them on fleabay for you.

Offline BigAl

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Re: Alternative wiring connectors for multi junctions
« Reply #8 on: January 09, 2019, 06:01:40 PM »
As Brian mentioned you will require a 'w' crimp tool for non-insulated terminals.
The 2.8mm connectors that you have chosen are ideal for areas with limited space (head light shell) most Kawasaki triples have them.
The problem that I have found with the 2.8mm terminals is that the terminal material thickness are not the same (approximate size- pin 0.40mm socket 0.25mm)
From experience (loose wires/broken terminals), I now use 2 type's of 'w' crimpers (as image) heavy tool for the pin/lighter tool for the socket
Current bikes:-
Honda CB750 K4 (1974) USA
Honda XL500S (1980) UK
Honda CD175 sloper (1968) UK
Honda CB1100A (2013) UK
www.alans-electrics.co.uk

Offline 71 V12

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Re: Alternative wiring connectors for multi junctions
« Reply #9 on: January 09, 2019, 08:10:03 PM »
My auto electrician mate has lent the crimp tools. Just waiting for the components to be delivered to have a go😁

Many thanks for your kind support.

Kevin

Offline 71 V12

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Re: Alternative wiring connectors for multi junctions
« Reply #10 on: January 12, 2019, 06:17:16 PM »
Well I ordered 2 and 3 way 2.8mm mini connectors and changed all of the multi-way bullets to these connectors. Having the correct crimping tool is essential and the terminals are fiddly particularly when crimping two wires. But like all things a bit of practice and you soon get the technique.

I am really pleased with the result, nice secure latched connectors, much more secure than the bullets and all electrics fully functioning. Hopefully long term reliability assured.
« Last Edit: January 12, 2019, 06:20:24 PM by 71 V12 »

Offline BigAl

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Re: Alternative wiring connectors for multi junctions
« Reply #11 on: January 12, 2019, 06:57:59 PM »
Very nice work, you did well to get 2 wires into a 2.8mm terminal.

Excellent detail work on the K4, just curious why the earlier 'k' indicator stems are fitted?

Alan
Current bikes:-
Honda CB750 K4 (1974) USA
Honda XL500S (1980) UK
Honda CD175 sloper (1968) UK
Honda CB1100A (2013) UK
www.alans-electrics.co.uk

Offline 71 V12

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Re: Alternative wiring connectors for multi junctions
« Reply #12 on: January 13, 2019, 01:22:42 PM »
Hi Al,

Thank you, it was the feedback on the forum that led to me to this solution, so as usual an invaluable resource and tanks again for all the advice👍

I actually did realise the indicator stem are the earlier type. What is the difference?

Cheers

Kevin

Offline BigAl

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Re: Alternative wiring connectors for multi junctions
« Reply #13 on: January 13, 2019, 02:44:42 PM »
Hi Kevin,

The USA models (K3 onward) had a slightly longer indicator stem with a 'tapered' profile (image attached off my bike)

Alan
Current bikes:-
Honda CB750 K4 (1974) USA
Honda XL500S (1980) UK
Honda CD175 sloper (1968) UK
Honda CB1100A (2013) UK
www.alans-electrics.co.uk