Corrosion/Water Proofing Connectors
 

Hi,
My bike (650S L2 Pointy) was completely disabled by corrosion of the fuel pump relay connector. When I say corrosion, that's an understatement as one of the terminals in the connector was basically rotted away to a mess of blue paste and a couple of bits of copper.


The underlying problem is that the rear under tray isn't weatherproof so spray from the rear wheel gets under the seat and builds up in the spaces behind the battery as well as everywhere else under there. It's all in bits at the moment and I'm trying to work out how to seal the undertray and the snowplough etc.


However with the rear bodywork off it's also an ideal time to inspect and protect various wiring connectors that are normally inaccessible. So I'm looking for thoughts as to the best method. Previously I'd have just given a quick squirt of ACF50 into the female side, and reassembled. However up till now I've only been thinking of internal corrosion affecting the actual connecting surfaces. My experience with the relay connector suggests I need to protect the whole thing. I was considering melting wax into the connectors from the wiring side, virtually potting the whole thing.


Any comments welcome, and also any suggestions on waterproofing the rear wheel arch as well.


Thanks, Tony S

Re: Corrosion/Water Proofing Connectors
 

Careful use of dielectric grease and either shrink wrap or old bicycle inner tube and tape around the connection once back together.

Re: Corrosion/Water Proofing Connectors
 

Use GT85 in electrical connections, it is a water inhibitor and helps to protect to electrical connection. You could also use some battery grease/jelly on the outside of this to help prevent water ingress to the connections themselves.
As a final barrier I use Self Amalgamating tape as this is water resistant and works well. I have spotlights on my bike with the connections behind external bodywork wrapped in this. No issues at all in the years I've had it.

Re: Corrosion/Water Proofing Connectors
 

+1 for self amalgamating tape, I find the 19mm wide more usable than the more common 25mm stuff.. I use it on satellite cable joints and any out door cabling. If I have to cable tie any wiring to motorbike frame I also put a few turns around cables as a 'cushion' to stop wiring insulation from moving and chafing.

https://www.toolstation.com/self-ama...ir-tape/p23876

Re: Corrosion/Water Proofing Connectors
 

All of the above and Clear Nail Varnish(ASDA sell it dead cheap) is a great insulating lacquer :)

Re: Corrosion/Water Proofing Connectors
 

That or ignition sealant or a big ol lump of grease

ACF and gresase will do the job fine - fit a hugger though

Re: Corrosion/Water Proofing Connectors
 

http://ebay.co.uk/itm/Suzuki-SV650-K...IAAOSwxORdteAd

This doesn't look the best, but one of the cheapest. Pyramid plastics around £90 would be better

Re: Corrosion/Water Proofing Connectors
 

Thanks for all the suggestions. I ended up with all the tail bodywork removed in any case, to get access to the wiring harness, and I think the interface between battery tray and snowplough was not properly fitted. The tray sitting under the snowplough and not slotted into the slot. It's refitted properly and I've also sealed the join with silicone.

Connectors are sealed with wax at the moment, just because I had that to hand. I used Waxoyl and heated it with hot air gun to run right into the back or the connector blocks. I've only done the connectors that like they may be immersed if the wheel arch still leaks.

Huggers - I have a Pyramid rear hugger but I didn't like the rather naff bracket that wrapped around the swinging arm, so I made my own instead.

https://c1.staticflickr.com/3/2639/3...8b6886e5_b.jpg