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hmm. those wires shouldn't be like that.

  • Thread starter Thread starter growler
  • Start date Start date
G

growler

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hey all,

bought a gs850g a couple months ago and will be tinkering with it all winter to a)keep me out of trouble and b)have it tip top and ready to ride in spring. :D i was just going over the electrical and noticed these wires barely connected. when to examine more closely and when i touched the wires they just completely came apart. i'll be looking for a wiring diagram today, but do any of you know what this electrical connection is? if you are facing the fuse box, this is to the right of that. there is this plug and two other plugs totaling 3. can i buy just the plug and then reconnect the wires?

thanks in advance. this forum is amazing. so. much. information!

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I might have one of those plugs and some pins in my pile o'parts - and I'm local.

There's a link to my email in my user profile. Pull the plug out and take a pic of the other side too and send it to me.
 
Go on Basscliff's site and there will be a manual for your bike that you can download. It will have wiring diagram in the back. Some of that appears to be part of the wiring connected to your r/r, may indicate problems of overheating of system. There should be article about testing system on Cliff's site also, called Stator Papers. terrylee
 
will do. i'll try to get at it in the next couple days. i'll email you once i have it out and take some more photos. thank you


850GT_Rider said:
I might have one of those plugs and some pins in my pile o'parts - and I'm local.

There's a link to my email in my user profile. Pull the plug out and take a pic of the other side too and send it to me.
Click to expand...
 
thank you, i'll check it out.

terrylee said:
Go on Basscliff's site and there will be a manual for your bike that you can download. It will have wiring diagram in the back. Some of that appears to be part of the wiring connected to your r/r, may indicate problems of overheating of system. There should be article about testing system on Cliff's site also, called Stator Papers. terrylee
Click to expand...
 
I see a link for 1980 GS850G wiring diagram. Would that be applicable to my 1982?

terrylee said:
Go on Basscliff's site and there will be a manual for your bike that you can download. It will have wiring diagram in the back. Some of that appears to be part of the wiring connected to your r/r, may indicate problems of overheating of system. There should be article about testing system on Cliff's site also, called Stator Papers. terrylee
Click to expand...
 
You can remove the old metal connector prongs from the nylon-plastic and crimp new ones on ...of course you need to pull the plug first because you need to access the prongs' locking tabs from the front side.... I use the smallest Dollar-store jewellers' screw driver to push the tiny locking tab down and pull out the old prong .


You will have to cut those corroded wires back a bit! Hopefully, there's enough slack in the total length after to push the repaired plug back in..This could be the hardest part of the repair- having the available length.
 
Just put the colours back to match the ones coming out the back. Judging by the colours alone,these are the A/C output from the stator connecting to the Regulator/Rectifier. The red one will be the R/R's dc output,that charges the battery.
 
Gorminrider said:
Just put the colours back to match the ones coming out the back. Judging by the colours alone,these are the A/C output from the stator connecting to the Regulator/Rectifier. The red one will be the R/R's dc output,that charges the battery.
Click to expand...

I didn't pay attention to the wire colors - probably should have.

If those are indeed the stator wires, I'd bypass that plug completely & wire them directly. Many many posts and threads on that.
 
great, thank you.

850GT_Rider said:
I didn't pay attention to the wire colors - probably should have.

If those are indeed the stator wires, I'd bypass that plug completely & wire them directly. Many many posts and threads on that.
Click to expand...
 
..solder's ok but need be done in the middle of wires- as 850GT says above take the connectors right off if you are going to do this.
...If you get the idea to solder to the old metal lugs without a real attention to how it'll stress the copper wire.....well, what I mean is, the extra solder hardens the connection there by thickness and maybe heat because and what happens is, it often breaks later where the copper whire leaves the "fix", where a wire-to-wire soldered splice can sort of float and not stress.
 
is there a good way to connect them without soldering?

Gorminrider said:
..solder's ok but need be done in the middle of wires- as 850GT says above take the connectors right off if you are going to do this.
...If you get the idea to solder to the old metal lugs without a real attention to how it'll stress the copper wire.....well, what I mean is, the extra solder hardens the connection there by thickness and maybe heat because and what happens is, it often breaks later where the copper whire leaves the "fix", where a wire-to-wire soldered splice can sort of float and not stress.
Click to expand...
 
Not if you want it to last.

These wires take so much current that the least bit of corrosion or a high-resistance connection leads to melted wires & connectors. Unless you have a sealed connector, then stripped, soldered, covered by heat shrink is the best way to go.
 
Do it Right

Do it Right

Brush with CLR, rinse well.
Flux & Solder.
Crimp curves a little.
Spritz with WD40, Good as Gold,,..
P1110894.jpg
 
Actually properly done crimp connectors are as good as anything. The junk they sell at Walmart ain't it.
 
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