Electrical connector problem.

hi

i posted about an intermittent ignition problem a while ago which ment that my ignition sometimes wouldn't switch on until i wiggled the handlebars and was told to look for a green plug, which should be the problem.

Took the bike appart today and found that this was indeed what the problem was, but i was expecting it to just be a loose connection, but it seems like the connector has in part melted! I have photos attached.

does anyone know how i should go about fixing this, or why it has actually happened in the first place, i cant see any reason why the wire would be shorting out or would it have happened just because of the bad connection.





cheers!

[Dave20046]

lovely, either corosion or bad wiring I think. Did a fuse go recently?.
Anyhow I think you can buy block connectors pretty cheaply and just remove the old plug and fit your own. Other than that you could fit a new loom which would hopefully eliminate the possibility of other undiscovered nastys. Wouldn't bother myself though.
While you're at it check all other block connectors you can ; i.e open them scrape any connections clean and spray them with wd40 or wd40 equivelent or some other anti rustation solution.

no fuse has gone that im aware of, any idea where im likely to find one othe same connector boxes? or is it better to jus buy a complete new one and fit it myself

[Dave20046]

Originally Posted by warrenhewitt10

no fuse has gone that im aware of, any idea where im likely to find one othe same connector boxes? or is it better to jus buy a complete new one and fit it myself

Dunno new looms like £30 and half a days work...and I don;t like work - I'd go to any little electrics shop or maybe a motorfactors and pick one up. I used to go to a little family run electronics shop for them, like 50p.
It doesn't even necesarily (as far as I can see) have to be a connector block you replace it with. As a temp measure you could cut the wires;strip them and solder them together or just get some male/female connectors and insulation tape.

My old Honda CB350SG had a simmilar problem with the H4 light connector.
The light kept cutting out and i found the block looked burnt on one of the pins. I found a block similar to it on a classic car website and got it soldered to the loom.

would the block have burnt just because the connection was continuously flicking on and off do you think? im gonna go connector box shopping in the morning before work i think

[Sid Squid]

The female piece of the connector has become slack, and/or dirty, the current passing through the connector thus has to pass only through a small area causing heat, and often arcing, which has in turn melted the block.
Either pull the connector apart then clean and reshape the connector and refit, or pull the wires from the block and use a separate connector outside it, both have been successfully done in many circumstances.

Hi, as a guide/source of connector blocks/plugs/sockets etc may I suggest looking on line at Maplins many local stores, or distributors like RS componants and Farnell, in particular RS who carry vast ranges for industry etc wher your more likely to find a matching replacement.
More importantly you you need to assess the cause of the the problem, I would be inclined to support the damp arcing theory.

Regards Icanopit

thanks for all the responses i got a connector block today and just changed the connector the wire that was dodgy, and left all the rest in the origional connector block as they seem to be fine, seems to have solved the problem, i can now turn left and not have to worry about the bike switching off, wot a novelty haha

[Dave20046]

weldone