hmm. those wires shouldn't be like that.

[Gorminrider]

..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.

[growler]

is there a good way to connect them without soldering?

..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.

[850GT_Rider]

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.

[Wizard]

Do it Right

Brush with CLR, rinse well.
Flux & Solder.
Crimp curves a little.
Spritz with WD40, Good as Gold,,..

[tkent02]

Actually properly done crimp connectors are as good as anything. The junk they sell at Walmart ain't it.

[growler]

great. i'll work on this over the weekend. you're right, best to do it correctly.

[850 Combat]

I still prefer to solder and shrink the stator wires to the R/R wires. Properly done crimps are easier said that done. We spend hundreds per crimper at work, and have to calibrate them daily or weekly, depending upon how they are used.

[growler]

i think this is the way i'm heading. watched a few youtube soldering videos, and did some other research online. i'll practice on some old wires first and once i'm confident i'll solder them and shrink, nice and neat.

I still prefer to solder and shrink the stator wires to the R/R wires. Properly done crimps are easier said that done. We spend hundreds per crimper at work, and have to calibrate them daily or weekly, depending upon how they are used.

[850GT_Rider]

i think this is the way i'm heading. watched a few youtube soldering videos, and did some other research online. i'll practice on some old wires first and once i'm confident i'll solder them and shrink, nice and neat.

PM sent........

[hikermikem]

...i'll solder them and shrink, nice and neat.

Not saying this ever happened to me , but don't forget to slide the heat-shrink tubing on the wires BEFORE you make your beautiful solder joints.

[850 Combat]

Be sure to test your stator and R/R before soldering it.

[growler]

finally got the garage space cleaned out, and all my winter basement projects moved back outside in the clean space. now to get a comfy garage chair.

going to test the stator and R/R, then solder. hoping i don't have to replace those...

[growler]

is there a specific kind of solder to use? do i need flux? or is rosin core ok?

[Steve]

is there a specific kind of solder to use? do i need flux? or is rosin core ok?

Rosin core is GREAT. The rosin is the flux.

If you can, look for solder that is NOT "lead-free". I find it just a bit harder to work with. A 60/40 blend will do just fine.

Do NOT use acid core solder that will be found in the plumbing department of the "big box" stores.

With rosin core solder, extra flux is not necessary, but there are just enough times that it will help. A small tin will last nearly a lifetime for the average amatuer mechanic.

.

[850GT_Rider]

is there a specific kind of solder to use? do i need flux? or is rosin core ok?

Welcome back after this lousy winter!

Where are you at in the metro Milwaukee area? I've got soldering gun, solder, heat gun, heat shrink tubing, etc etc. Be more than happy to lend you a hand.

Woke mine up from it's winter nap on Friday. Got done just as the rain started, so still haven't been on the road. Now today of course, it's snowing like it's November. Forecast sux too....