Wiring issue FZS600 (02)

[Dave4521]

HiH
HiH
Hiya

HiH
HiyaHiya Got an issue with one indicator intermittently not working while the front panel instrument goes bananas, showing full tank, wrong indicator flashing (actually solid) and other anomalies. Traced it to one loose fitting wire in the female section of the terminal block (black-coloured wire in pics).  Looks like the plastic around that wire is burnt and I assume this means the whole block will need replacing rather than just the end pin on that black wire?

Anyhow, just looking for suggestions as to where to find the appropriate block. Maybe B&Q?

I'm not that confident with pressing new pins onto wires so, if I'm going to fix it myself, it will ideally need to be a block with screws. Will cut all the wires in the female section of the block and fit them into the new (screw) terminal individually. 

The far more expensive option is to get a shop to do it of course, although cheaper than me frying the whole bike

Thanks

[bandit]

Whats wrong with the terminal block apart from needing a clean.

[Dave4521]

Hi. Possibly nothing.  But the aformentioned wire is loose.  When I move it slightly with my fingers and hold it steady, then the electrics work okay.  When the bike moves (and thus that wire), then the electrics malfunction as described.  I'm just wondering whether it's burnt the area around it, meaning the whole block should ideally be replaced for safety reasons

[bandit]

Hi, you could cut the wires each side of blocks use 2 small screw terminal blocks with suitable short length of wire to bridge gap & wrap in self amalgamating tape for waterproofing,but I personally would remove the female connector from the block with a very small screwdriver you should see a tang inside the block that needs holding down while you pull on the wire,then you can clean terminal, bend it a little if it needs to make fit tighter to male spade, inspect the block.   

[Dave4521]

yes, on reflection, it would probably make sense attempting to clean and straighten that one pin before replacing whole damn block.



Do you insert the screwdriver from the outside of the female block (where the wire enters) or inside it near the pin and contacts?  (not by my bike as type)

[bandit]

Not sure myself they do differ depending on pins as it is hard to see in pic but the terminal looks like it will exit from the rear of block (wire end) as the block molding stops it coming out, my guess is look in the other near the pin & contacts for the tang to release from the block.


Try pushing down the top part of the pin nearest your thumb on the terminal to remove in pic 1 & lightly pull on wire.

[Dave4521]

Coolio, thanks will give it a try tomorrow.

[bandit]

Had a bit of a search & found this site & I think this is the type of terminal you have,note the tang on the top of pin as I said.


  https://www.lambertsbikes.co.uk/product/2-8mm-automotive-electrical-connector-terminal-pins/

[Dave4521]

yes, I can see it clearly.  Good to know where to find them if I need to. Cheers!

[Disorderlypunk]

DO NOT USE A TERMINAL BLOCK
worst case scenario if cleaning it out wont work is to strip back a bit of wire either side of connector on damaged wire and solder on a new piece either side with a male and female connector inbetween - will look tidier will be easier to disconnect and will be less likely to break again than a terminal block
-will have a look in my box of bits tommorow and see if i still have that bit there from my koso(ish) conversion

[Dave4521]

okay, thanks for the advice...