electrical problems
 

last night my xtr died on the way home from work, clock showed engine management light and code 33, which I believe is open circuit on coil primary circuit
anyway i have stripped it tonight and found several terminals under the tank on the left hand side are corroded and have just come out of their blocks as I touched them
so where is the best place to get new terminals of the correct type to refit into the multi plugs, or should i just connect them with whatever terminals I can get
oh yeah my 25 mile ride home took me from 5.40 to 11.15!

These guys are great, they have everything you'll need, including the tools to remove terminals from their blocks...

http://www.vehicle-wiring-products.e...ldingterms.php

just been looking at their website, but confused as to which terminals I need
suppose I need to pull the terminals out and measure them

Ive no info on where to get new terminals but its a common fault with the R/X, and the wiring is really bad workmanship its unreal. I had my kill switch wire corrode through once and lucky enough it was a saturday and was only down the road from home so could get picked up easy.

Lucky enough the rest of the connectors were not too bad, so i just silconed all the ends and the connectors, then made a home made rubber flap to stop any direct water or road crud from just bay passing the forks and going straight onto the connectors.

The Yamaha connectors are no good for sealling the terminals & most don't have seals, so it's of little use just renewing the terminals the fault will come back one day. If you really become stuck cut the Yamaha plus off, solder the wires together & heat shrink the wiring to seal the loom.

Or use one of super seal connectors

http://www.google.com.au/images?q=superseal+connectors&rls=com.microsoft:en-au:IE-SearchBox&oe=&redir_esc=&um=1&ie=UTF-8&source=univ&ei=73DcTIr1KZHcvQPKi4HzCQ&sa=X&oi=im age_result_group&ct=title&resnum=2&ved=0CDIQsAQwAQ &biw=1276&bih=878

http://www.vanline.com.au/VPDF/Superseal.pdf

Or MTA connectors

http://www.proquip.com.au/Product%20Pages/MTA/MTAConnectors.html

kev I'm liking the solder and heat shrink option, I use my bike all year round so the unsheilded plugs are a breakdown waiting to happen
so its break out the soldering iron and make some permanent joints

I have done this many times in my life to stop electrical problems.

my head says it must be repaired as per original, thats just the way I have always thought. but neatly soldering and heat shrinking the wires together is an altogether more permanant fix has to be the best method for a trouble free, reliable system
thanks for your help, i'm at work today but will sort it when I get home

OK did the electrical prob yesterday, removed 3 plugs with corroded terminals soldered the wires together and insulated with a double layer of heat shrink, then sprayed everything including all the other plugs everywhere else on the bike with ACF 50
bike fired and run first prod! so off down the road for a test ride, only a few hundred yards off and I have a rear puncture. Back home V slowly and remove rear wheel and tyre, badly gashing my knuckle in the process,
so innner tube out minus valve not sure as yet if the tyre crept because pressure was low due to an actual puncture and ripped the valve out or it was simply a valve failure, too much blood on the scene to investigate properly, so went to lick my wounds literally!
if it wasn't for bad luck then I would be totally luckless :009:

bike now all back together, no pucture in the old tube just corrosion between valve and rim making the valve part company from the tube, either that or it had a slow leak from the valve (tyre pressures were always good though) no way of knowing now though