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Broken connectors

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sk10
L Plate Warrior



Joined: 09 May 2020
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PostPosted: 13:48 - 09 May 2020    Post subject: Broken connectors Reply with quote

Been riding on 125 Sinnis Apache(2014) for 2 years on a CBT.
The Battery needed charging and when I took it out the wire ends were so corroded that two of them came off.

Am best buying a new wire harness or can I easily find the correct ends and replace them myself? Bear in mind, I have no experience besides just doing oil and fluid checks.

The green wire had a gold end but the red had a silver. I found one that looks similar to the red wire on amazon but does it have to be a specific type? A specific power or current rating? Will it not work if I just use some generic similar looking type? And for the green wire, could I just replace it with a silver one aswell as Im finding it hard to find?

https://i.ibb.co/f2x5ygS/20200307-164350.jpg

https://i.ibb.co/r6KDWKS/20200307-160544.jpg

The green end should look like this.
https://i.ibb.co/dG70Y0C/green-wire.png
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Nobby the Bastard
Harley Gaydar



Joined: 16 Aug 2013
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PostPosted: 13:56 - 09 May 2020    Post subject: Reply with quote

Any connector that will attach to the other side will do.
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 14:08 - 09 May 2020    Post subject: Re: Broken connectors Reply with quote

sk10 wrote:
Been riding on 125 Sinnis Apache(2014) for 2 years on a CBT.
The Battery needed charging and when I took it out the wire ends were so corroded that two of them came off.

https://www.eurocarparts.com/p/ring-connectors-35a-6mm-hole-BAR230 (£0.59p)

But unless you're a "key worker" or pay delivery....

So.

https://www.halfords.com/tools/fuses-electricals-and-fixings/electricals/halfords-ring-connectors-hef144-30-amp%2F6mm-207456.html (1.80p !)

You will also need a crimping tool or solder.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 14:12 - 09 May 2020    Post subject: Reply with quote

They're called ring terminals or lug rings. Various sizes. The hole needs to be big enough to fit your bolt through and the crimp needs to be big enough to hold that fairly large bundle fo wires.

The colour is largely irrelevant.

It'll be electric start so they will need to be faily heavy duty ones. Which they will be if they are big enough to hold that diameter of wire.

Cut the damaged end off the wire, strip the insulation and apply the new terminal. Ideally using a crimping tool.

If you can get ones with a crimp that holds the insulation too, it'll help prevent water tracking back up the insulation.

Smear vaseline on them after fitting to stop them corroding again.
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 14:14 - 09 May 2020    Post subject: Re: Broken connectors Reply with quote

Riejufixing wrote:


Will they cope with electric start?

Maybe these?
https://www.halfords.com/tools/fuses-electricals-and-fixings/electricals/halfords-battery-lead-connectors-hef145-207464.html
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 15:28 - 09 May 2020    Post subject: Re: Broken connectors Reply with quote

stinkwheel wrote:

The ECP/Halfrauds ones look like the originals. Those other ones are big, might not go on the cable or terminal. I don't know what the current draw would be, but I'd guess 35A would be more than enough. I wonder whether there's a fuse involved anywhere? That would be indicative.

EDIT: That's quite hard to find. Apparently a YBR125 has a starter motor is 400W (service manual), which may also be indicative.
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sk10
L Plate Warrior



Joined: 09 May 2020
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PostPosted: 15:36 - 24 May 2020    Post subject: Reply with quote

It turns out you were both right. The main earth wire is thicker and so I needed the bigger ring to fit the wire in. And the yellow ones went with the thin live wire. There was no problem getting the bike started except that it needed warming up.
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