Melted connector

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  • Quick Cal
    • Jan 2026

    #1

    Melted connector

    I have the evil melted connector inside the headlight bucket. Mine is a 6 pin. I have not had any electrical problem's at all.

    What have you guy's used for a replacement connector. I guess I could just cut it off and use male and female bullet connector's,,especially since I just bought a $35 Professional grade crimper. But I hate to rig it that bad. I could see future problem's down the line. Ideally I would like to be able to just remove the wire's from the melted plug and put them in the new plug. Anyone know what size the terminal's are.

    Anyone happen to have the proper connector,,, or at least know where to get one. Thanks.

    Last edited by Guest; 07-02-2012, 08:58 PM.
  • Nessism
    Forum LongTimer
    GSResource Superstar
    Past Site Supporter
    Super Site Supporter
    • Mar 2006
    • 35766
    • Torrance, CA

    #2
    I keep telling everyone about that out and back stator loop, but most people don't fix the wiring until it melts down.
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

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    • cowboyup3371
      Forum LongTimer
      Past Site Supporter
      • Apr 2010
      • 13996
      • In Ohio Now

      #3
      I would honestly just get new terminals and a new connector from someone like www.vintageconnections.com or Cycle Recycle II (http://www.newmotorcycleparts.com/). They are both real good and real inexpensive while maintaining the classic look of the bike. You'll pay well under $10 for that one connector
      Cowboy Up or Quit. - Run Free Lou and Rest in Peace

      1981 GS550T - My First
      1981 GS550L - My Eldest Daughter's - Now Sold
      2007 GSF1250SA Bandit - My touring bike

      Sit tall in the saddle Hold your head up high
      Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
      and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

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      • Quick Cal

        #4
        Thanks for the link cowboy. I got an OEM style from cycle-re-cycle.

        So can someone pull theirs apart and tell me which end has which spades connectors. I might as well make it right. Thanks.

        Comment

        • JEEPRUSTY

          #5
          left is female right is male

          Comment

          • Quick Cal

            #6
            So the main harness side is male. Correct?

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            • cowboyup3371
              Forum LongTimer
              Past Site Supporter
              • Apr 2010
              • 13996
              • In Ohio Now

              #7
              Quick Cal, it doesn't really matter which end you make which. Do it based on your needs, desires, and what works best for your harness.
              Cowboy Up or Quit. - Run Free Lou and Rest in Peace

              1981 GS550T - My First
              1981 GS550L - My Eldest Daughter's - Now Sold
              2007 GSF1250SA Bandit - My touring bike

              Sit tall in the saddle Hold your head up high
              Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
              and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

              Comment

              • Quick Cal

                #8
                Originally posted by cowboyup3371
                Quick Cal, it doesn't really matter which end you make which. Do it based on your needs, desires, and what works best for your harness.

                As long as I don't want to change the starter button/off-on/ switch it doesn't matter. But if I needed to change that down the road sometime it would matter.

                Heck. All I had to do was look down inside the new plug and I can see how it goes.

                Comment

                • Nessism
                  Forum LongTimer
                  GSResource Superstar
                  Past Site Supporter
                  Super Site Supporter
                  • Mar 2006
                  • 35766
                  • Torrance, CA

                  #9
                  I believe the male attaches to the hand control.

                  You can check ebay for photos of hand controls to confirm.
                  Ed

                  To measure is to know.

                  Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                  Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                  Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                  KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                  Comment

                  • Quick Cal

                    #10
                    Originally posted by Nessism
                    I believe the male attaches to the hand control.

                    You can check ebay for photos of hand controls to confirm.
                    You are correct in that the male plastic part of the connecter goes to the hand control. Female on the main harness. I worded it kinda goofy and was actually talking about the metal spades. But all you have to do is look at the connecter and you can figure it out.

                    Do you have a link for this wire loop thingy you're talking about. Thanks.

                    Comment

                    • Nessism
                      Forum LongTimer
                      GSResource Superstar
                      Past Site Supporter
                      Super Site Supporter
                      • Mar 2006
                      • 35766
                      • Torrance, CA

                      #11
                      Originally posted by Quick Cal


                      Do you have a link for this wire loop thingy you're talking about. Thanks.

                      [/IMG]

                      Look at your wiring diagram. Trace the stator wires and look for the white/red & white/green.
                      Ed

                      To measure is to know.

                      Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                      Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                      Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                      KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                      Comment

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