Fried Toasty Brown Connector

[loungesurfer]

I know there are lots of other postings showing their melted brown connector, but I thought I'd add my own.

I was reading all the charging/brown connector threads earlier this week and decided I needed to check mine and fix the connector soldering. We'll I'm sure glad I checked while it was in the garage. The whole right side of the connector leading to the rectifier was completely fried! (photos are attached). I'm a little surpised it fried on the side leading to the retifier given they are properly soldered and the other side leading away was not. Guess it doesn't really matter.

The fix was to replace the connector with the Posi-Lock connectors someone else used. Niffty little connectors! Thanks! All's back in order now.

Thanks to all who have shared their similar connector stories.
Denys - aka Loungesurfer

[keithroxx]

what year and how many miles are on your Fut?

[ib12]

Great to see quality parts are used in putting together this bike eh.

[drakis2004]

Yikes - glad you didn't get stranded. Anyone know where these connectors come from or how to get some? I'd love to set up a test bench and run a batch through a series of controlled tests.

If you haven't eliminated the brown connector yet, do yourself a favor and replace it by soldering the connections or getting some better connectors. My Aprilia shop (which shall remain nameless, because they usually provide top service) told me to just keep the brown connector clean and tidy, and I'd have no problems. It melted two weeks later.

[rdbandkab]

You should be able to get the Posi-Locks at most Autozones and the like. Even one of the Marts(K or Wal) may carry them. Check the sizes and they even have temp ranges on some.

rdb

[bikpaintr]

Soldering only one side of a male/female connection doesn't really accomplish much as they are locked together & both will overheat. As many times as this has been mentioned on this forum I'm surprised that anyone is still riding around with an unsoldered brown connector.

[loungesurfer]

what year and how many miles are on your Fut?

It is a 2004 with 6,200 miles since I purchased it in March 2005.

As many times as this has been mentioned on this forum I'm surprised that anyone is still riding around with an unsoldered brown connector.

You're correct - I should have replaced it sooner, but delayed until now. Luckily it was parked at home and not stranded somewhere in San Diego County.

Thanks,
Denys

[mgtx73]

Wow, that one looks like mine did. Unfortuneately for me I was left stranded away from home with the misses on the back with a dead battery as I came to a stop sign. Got it fixed at AF1 though.

[Dan]

As many times as this has been mentioned on this forum I'm surprised that anyone is still riding around with an unsoldered brown connector.

(Raising hand) For 58k miles.

[rowdy lee]

With all the connector work going (and gone) on, has anyone found their connectors packed full of dielectric grease like mine was?

My bike is #50 and appearently (sp?) was greased at the factory. Did they not continue the practice during the run?

I did the wire mod anyway but I'am still on the original connectors, battery, fuses, solenoid, etc. etc.

[TxRider25]

I took my brown connector apart and soldered all the terminals soon after the failures started being posted here which was, I think, about 2 years ago. Plus I've been using De-Oxit on those therminals. Then I did the wiring mod 12 months ago. Now I've only got 10k miles on my 2002 and so far no problem. BUT, every time a new failure is posted I wonder if I'm doing the right thing by leaving that brown connector in place. Hmmm...

Has anyone had a failure that has soldered all the terminals and used an anti-oxident on that connector?

[bikpaintr]

With all the connector work going (and gone) on, has anyone found their connectors packed full of dielectric grease like mine was?

My bike is #50 and appearently (sp?) was greased at the factory. Did they not continue the practice during the run?

I did the wire mod anyway but I'am still on the original connectors, battery, fuses, solenoid, etc. etc.

I never saw any signs of dielectric grease in the connectors on my 02 & I'm glad of it. Still got my original connectors (both soldered), fuses, solenoid but the battery was replaced once.

[rowdy lee]

IMO, the grease or compound or call it what you will, probly keeps corrosion and oxidation and oil mist and road grunge out of the plug-connectors... any of which would increase resistance... not a good thing certainly, and probly contributors to failure... if not a general "weakness" ... sub-par performance in the system

But, I'am not an EE and don't give a F about mechaniking or even speculating any more... so, whatever.

[CarlosT]

File your complaint here...as should all you f_ckers with toasted or grilled cheese brown plugs

http://www-odi.nhtsa.dot.gov/ivoq/

[bikpaintr]

IMO, the grease or compound or call it what you will, probly keeps corrosion and oxidation and oil mist and road grunge out of the plug-connectors... any of which would increase resistance... not a good thing certainly, and probly contributors to failure... if not a general "weakness" ... sub-par performance in the system

But, I'am not an EE and don't give a F about mechaniking or even speculating any more... so, whatever.

If applied properly dielectric can be good for waterproofing a connection. Unfortunately it is often smeared all over the electrical connections & since it is non conductive it can cause more problems then it will prevent. In a situation like the brown connector which does seem to get hot I'd be afraid of the grease melting & seeping into the male/female connections.