The member photo gallery is now integrated and live!!  All user albums and pictures have been ported from old gallery.


To register send an e-mail to admin@bmwr65.org and provide your location and desired user name.

Author Topic: Newbie - Hi-Beam Problem  (Read 5156 times)

Offline montmil

  • Mt. Olympus Resident
  • ****
  • Posts: 8371
Re: Newbie - Hi-Beam Problem
« Reply #30 on: April 24, 2014, 02:01:31 PM »
Separating the two connector halves is going to be the best way to make a proper repair.

BMW rarely soldered terminal connectors to the wires. Instead, a double-crimp was used whereby the first crimp rolled a portion of the metal connector over and onto the wire. The second crimp did the same thing but grabbed tight to the wire insulation. These connections resisted, to a degree, the damage that might occur earlier with a rigid, soldered connection.

To determine if you need a male or female terminal, the connector must be separated.

You mentioned the terminal for this wire is long gone. The raw end of the wire may have failed do to corrosion, excessive flexing, or a ham-fisted PO. The terminals usually stay in the blocks. Let's just blame the PO for this.

Your local electronics store -we call 'em Radio Shack 'round here- should have a terminal to suit. That's another reason to pull the connector apart; you need to know the correct size. The new terminal does not have to be the double-crimp style but it must fit its male or female counterpart. If all you can find are terminals with the plastic bits, cut off the plastic as it obviously ain't gonna fit into the block.

Couple points: The terminal connectors are held within the connector blocks by a small tang that goes in easy. To remove a terminal, use a very small flat-blade screwdriver to locate and depress the tang while you gently pull the terminal clear. Refit is cake.

While at the store, pick up a small tube of dielectric grease and treat every terminal you come across with a light smear. Prevents corrosion. Insures good electrical performance. Battery terminals also love this stuff. There is also a spray can product of terminal cleaner that will not damage plastic nor paint. Good to use as you can shoot some into a connector block and see gunk drip onto your shop towel. Using both products can add years of performance to your circuit's life.

Fix it proper and fugitaboudit.  Hope this helps you to "see the light".
Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet

lukasgrech

  • Guest
Re: Newbie - Hi-Beam Problem
« Reply #31 on: April 24, 2014, 02:51:59 PM »
Thanks Monte, I have seen the light! I'll have a go at it and see what I manage to do.

Cheers!

Offline georgesgiralt

  • Mt. Olympus Resident
  • ****
  • Posts: 1388
  • I Love YaBB 2!
Re: Newbie - Hi-Beam Problem
« Reply #32 on: April 24, 2014, 03:48:39 PM »
Hello !
To remove the pins from the connector, you need a feather as they call it in the trade. It is a very thin wall tube you put into the connector from the contact side. It will press the locking tabs and then you can pull the wire and it will draw the pin out of the housing.
As I no longer work in aircraft manufacture where this tool is very common, I had success making one with an aluminium beer can and a pair of scissors.
Worst part was to keep my fingers free from blood...But you get the idea. something hard enough you can make into a small cylinder to fit between the pin and the casing. Plastic sheet is fine too.
Edit : you may find male pins on the accessory plug which, if like my bike, are unused... Just isolate the wire and you're done.
« Last Edit: April 24, 2014, 03:51:36 PM by georgesgiralt »

lukasgrech

  • Guest
Re: Newbie - Hi-Beam Problem
« Reply #33 on: April 25, 2014, 03:51:37 AM »
Thanks George, will definitely use that.

Question about Dielectric grease. Here in the UK, nothing of that name seems to exist. Is it the same as a silicone grease?

AlfromNH

  • Guest
Re: Newbie - Hi-Beam Problem
« Reply #34 on: April 25, 2014, 05:44:04 AM »
So you've found that there are separate wires running from the switch to the main loom for high beam "on" vs high beam "flash"? I didn't see that coming :-?

lukasgrech

  • Guest
Re: Newbie - Hi-Beam Problem
« Reply #35 on: April 25, 2014, 05:47:25 AM »
Yep, you can see how that runs in the wiring schematic posted above. Seems strange..


Offline Barry

  • Mt. Olympus Resident
  • ****
  • Posts: 5145
Re: Newbie - Hi-Beam Problem
« Reply #36 on: April 25, 2014, 06:23:41 AM »
Dielectric grease is not hard to find in the UK but I'd use silicone grease if I already had it.

Dielectric grease is a silicone grease perhaps with more thickening agents.
Barry Cheshire, England 79 R45

lukasgrech

  • Guest
Re: Newbie - Hi-Beam Problem
« Reply #37 on: April 26, 2014, 11:03:22 AM »
Woo! To the right of the photo, you will see I have Hi-Beam!

The terminal was still in the plug, and in pretty good condition after a bit of cleaning, so I removed the botched wire, and soldered on a new wire end, and that to the terminal. Easy as..




Offline montmil

  • Mt. Olympus Resident
  • ****
  • Posts: 8371
Re: Newbie - Hi-Beam Problem
« Reply #38 on: April 26, 2014, 02:43:08 PM »
I love it when a plan comes together.  - Hannibal

Smith. Not Lecter
Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet