Hmm I thought you wanted to replace both a male and female plug, if you want one to fit straight into the Honda one you might have trouble.

dobbslc wrote:Hmm I thought you wanted to replace both a male and female plug, if you want one to fit straight into the Honda one you might have trouble.

I didn't know that was doable. Is the female easy to take off?

No? Not sure what he's talking about? Your after a replacement reg/rec plug yeah? Maybe check with rick oliver for a quick replacement, as the plug is a common problem... That or in the meantime you could take the wires out, crimp a spade receptacle onto the wires and connect directly? Never tried that though...that or as said above, solder the wire into the connector plug if it is still in good nick?

Icemaestro wrote:No? Not sure what he's talking about? Your after a replacement reg/rec plug yeah? Maybe check with rick oliver for a quick replacement, as the plug is a common problem... That or in the meantime you could take the wires out, crimp a spade receptacle onto the wires and connect directly? Never tried that though...that or as said above, solder the wire into the connector plug if it is still in good nick?

Right I've worked out the problem. One of the plastic strips inside the plug which keeps the wire in place once crimped has snapped off a tiny bit. So there is nothing to stop the wire from coming out.

The dilemma I have is if I replace the plug and snip the wires, I won't have enough slack. So I'd need to replace the wiring. And whoever owned the bike before me did a terrible job of taping all the wires together, it will be such a pain to re-do everything.

I suppose soldering could work, but metal to plastic?? Wouldn't the plastic melt? Otherwise I could try and lodge a bit of plastic in there and crimp down?

If a failed contact retaining clip is the only reason the contact will not remain within the connector block, then simply push the contact onto the rect/reg splade using a srew driver after you have pushed the connector block into the rect/reg unit.

I suggest that the spring tension in the contact is also insufficient, it should not fall out or need to be taped to another contact. Crush the contact before inserting, it should require significant force to insert the contact onto the rect/reg spade, otherwise the connection will be poor. The tension in the other contacts in the connector block should also be checked. Low tension resulting in poor connections is the cause of burnt contacts and therefore charging system problems.

The spade bit in the male connector is held by a small bit of plastic..I'd just chuck a whole lot of solder on behind it to wedge it in place...when you buy one of those connectors off trademe they come disassembled from memory, so you could just destroy your current plug and put new spades and plug on the end :-)

+1 for magg's suggestion

The spade connector should be a tight fit onto the blade in the R/R - it's the mechanical contact that provides the surface area for the electrical current to flow. Too weak a grip and the current will flow through a very small area causing it to heat up and expand which causes a worse joint etc, etc. Heat will also soften the plastic of the connector housing so the terminals can come adrift.
Slide the spade terminals out of the plastic, they normally have a small tang which locks them in which can be pushed down with a small (jewellers type small) screwdriver. Then give the rolled over edges of the terminals a gentle squeeze with pliers to make them a snug fit on the R/R pins. Pop the terminals back into the connector and Bob's your mother's brother.

newtothis wrote:+1 for magg's suggestion

The spade connector should be a tight fit onto the blade in the R/R - it's the mechanical contact that provides the surface area for the electrical current to flow. Too weak a grip and the current will flow through a very small area causing it to heat up and expand which causes a worse joint etc, etc. Heat will also soften the plastic of the connector housing so the terminals can come adrift.
Slide the spade terminals out of the plastic, they normally have a small tang which locks them in which can be pushed down with a small (jewellers type small) screwdriver. Then give the rolled over edges of the terminals a gentle squeeze with pliers to make them a snug fit on the R/R pins. Pop the terminals back into the connector and Bob's your mother's brother.

If you read his post he said the little plastic bit that holds the spade in to the connector is broken, and that's the main issue?

That connector block is available. Honda Pn. 32110-MW0-305 is a repair kit that includes a wired plug, solder and shrink wrap.



Auto-electric places like http://kojaycat.co.uk/epages/950000457. ... nectors%22, Vehicle Wiring Products, Pole Volt and others also sell the connectors for reg/recs.

Ciao,

[/quote]
If you read his post he said the little plastic bit that holds the spade in to the connector is broken, and that's the main issue?[/quote]

But the spade terminal should hold itself onto the blade rather than require the plastic part to hold it in place. Yes the locating lug it broken but the spade is falling off the R/R because it's not sufficiently tight.
When I got mine there was no plastic connector housing at all, just the spades pushed onto the R/R, the electrical connections were fine.