Replacing old 6.3 mm terminal connectors with new 2.8 mm terminal connectors

[Guest]

Hello i am new in this forum and i have old Suzuki Katana GS650 1983 year. I have problem with charging, but my R/R and stator are okay...everything comes from weak connections cuz my bike is 31 year old and i bet no one change them. I found "3,9 mm Japanese bullet connectors" on good price on the net and some (2-3-4-6-9 way) connectors with 2.8 mm terminals. Is it good idea to change OEM connectors with 6.3 mm terminals with new one with 2.8 mm terminals? Does size matter and how will affect over performance.

Sorry for my bad English

Regards E.Genev

[OldVet66]

What matters is matching the terminals to the wire size range and use proper crimping tools. You can use vintage or modern connectors, your choice. The right crimper will turn the wings of the terminal around and back into the center of the wire strands like the ones on there now. There are also two crimpers for barrel type connectors, one for uninsulated and one for insulated terminals. You can get tools with jaw dies that will cover all types including ones for spark plug wires. FYI the newer waterproof connectors use the old style wings wrapped around two places on each terminal, so they are likely a little better than the barrel type.

[Nessism]

Best thing to do is rewire the charging system, bypassing the stock harness. Connect the stator directly into the R/R, and make sure the R/R is properly grounded. Most GSR members here use flat spade type terminals, not bullets, because they seem more reliable.