R100/7 died on the road.

[nhmaf]

Dang-ddiddly dang it!    The old '78 R100 had finally started to look like a trustworthy bike after much effort - and last week I had done a 60 mile loop on it.   So, I figured a wash and polish and fresh tank of gas for another 60 mile loop before I retorqued the heads and rocker arms after replacing the push rod tube seals and head gaskets and de-carboned the pistons was going to be easy-peasy.   I am glad that I decided to do some more local miles before venturing too far from home this weekend, as it shut down totally coming down a hill about 8 miles from home.  

Fortunately a friendly guy gave me a lift back home where I got my truck and trailer and retrieved my own dead airhead, which had absolute "0" electrical activity when it conked out.

Examination in the garage seems to indicate that the main/starter relay connection 87  in the relay socket was corroded (probably from the leaking m/c when I got it from the PO), and the vibration from riding on 5 miles of gravel road was enough to cause it to stop making contact. So, I had battery power to one terminal of the relay, but no power to anything else on the bike in order to light things up to start it.   Grrrr.   I'e managed to clean it up pretty well and it lights and starts fine again now, though I've now managed to screw up the power connection to the horn relay in the process, and will have to go back in to fix that... May have to see about replacing the whole relay socket assembly somehow to ensure things don't go bad again further away from home.



Has

[montmil]

Those freaking, under-tank Master Cylinders.  

I'd love to convert the one on my 1978 R100S to a bar-mount MC but the costs involved... well, slap me!

I had planned a nice ride and rolled the 'S' out to the driveway. Hit the starter button and... Nada. Nutting'. Quiet.

Rolled back into the shop and started poking around, wiggling wires and... A corroded, bare end of a wire fell free from the starter relay mounting block. I had a full R100 harness off FleaBay stashed and used the relay block as I added new terminals to every wire to the relay. Pretty sure the occasional MC overfill by the PO contributed to the terrible corrosion.

[nhmaf]

That one actually looks better than mine did (though no wire actually did fall out)!  

Did you use regular old SAE crimp terminals in your replacement, or did you find a source for the proper ones, Monte?

[montmil]

...Did you use regular old SAE crimp terminals in your replacement, or did you find a source for the proper ones, Monte?

I used the "proper" OEM-style terminals; the ones that utilize a 'rolled' crimp that captures both the bare wire and the wire sheath. Bought a nice wire plier that does a fantastic job of creating both 'rolls' with just one good squeeze. I've had enough frustration with POs use of those cheezy squashed terminals. Depending on the terminal's actual job, I may solder the bitter end to the terminal.

I may occasionally tease Brit Barry, but I too can be a bit anal with my wire work. :-D

[mrclubike]

That one actually looks better than mine did (though no wire actually did fall out)!  

Did you use regular old SAE crimp terminals in your replacement, or did you find a source for the proper ones, Monte?

Here is the real deal from Hella
http://www.partdeal.com/hella-cable-connector-term-6-3mm-w-catch-1-1-100-box-87272.html

Or you can get them from Max for $1.25 each
 61 13 1 352 810       CABLE SOCKET FEMALE

[mrclubike]

Here is the socket from Max

[BPT]

Montmil - what kind of pliers did you find that work so well?  Fancy expensive?

[georgesgiralt]

Hello !
I've got this one. Not sure it is the least expensive, though.
http://www.holden.co.uk/displayproduct.asp?sg=1&pgCode=082&sgName=Electrical&pgName=Wiring&agCode=0476&agName=Uninsulated+Connectors+%26+Tools&pCode=090.006
There are plenty. Try to buy from a guy having different set of crimping end. This way you'll buy only one tool for the AMP Fast On style connectors, AMP Junior Timer connector, etc...

[BPT]

Thanks georgesgiralt.  You're right, there are plenty.  I have some basic ones and was looking to upgrade.  Since there are so many it's always nice to have a recommendation from someone "in real life".

And I do like the idea of interchangeable dies, I guess I'd have to know what all I'd be needing it for.

[nhmaf]

Thanks guys!
I've also found this tool which might be suitable for those Hella terminals
http://www.dormanproducts.com/p-20721-85363.aspx?origin=keyword

http://www.dormanproducts.com/p-33237-85342.aspx?origin=keyword

These guys actually also sell a relay socket with the mounting screw tab on the back surface (which I'd use on the R100 as its relay mounts are vertical not horizontal like the R65) - but the socket they sell is prewired with some 18 gauge leads I'd have to remove as I won't want to splice those smaller wires into the harness.  That Hella socket looks like the right one

http://www.dormanproducts.com/p-10729-85170.aspx?origin=keyword

[mrclubike]

Thanks guys!
I've also found this tool which might be suitable for those Hella terminals
http://www.dormanproducts.com/p-20721-85363.aspx?origin=keyword

http://www.dormanproducts.com/p-33237-85342.aspx?origin=keyword

These guys actually also sell a relay socket with the mounting screw tab on the back surface (which I'd use on the R100 as its relay mounts are vertical not horizontal like the R65) - but the socket they sell is prewired with some 18 gauge leads I'd have to remove as I won't want to splice those smaller wires into the harness.  That Hella socket looks like the right one

http://www.dormanproducts.com/p-10729-85170.aspx?origin=keyword

The Dorman crimpers look very good for the money

The Dorman terminals you show WILL NOT Work

[montmil]

Montmil - what kind of pliers did you find that work so well?  Fancy expensive?

Here's a vendor that I have frequently used. Lots of electrical wiring goodies.

As to the crimping tool, I have an economical tool offered on their website. Part # ECT47 for $33.95. I like it primarily due to the 2-step crimp. If you don't do the dvl-crimp all the time, this tool is a good value.

http://www.cycleterminal.com/index.html

At the bottom of the Crimp Tool section, there is a nice tutorial on correct terminal crimping.

[BPT]

Oh yeah, I've been on that site before and have their link saved somewhere.  Lots of good stuff on there, thanks for the rec. on the crimper.

I wanted to get something better than the common "squisher" variety that I have.  But going to something like Knipex, NWS, etc. gets pretty expensive quickly.  I'll check this out.  And I like that they have other dies available.  

Pardon my ignorance but what do you mean by "dvl-crimp"?

[montmil]

...but what do you mean by "dvl-crimp"?

V and B side by side on keyboard.

[nhmaf]

I ended up ordering a handful of the Hella sockets and a 100-pack of Hella terminals for a Hella-good price from the partdeal.com website that Mrclubike linked to above.

I will be glad when I can start to trust the old bike's electrics again...