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FJR Motorcycle Forums
Technical & Mechanical Problems
STS Turn Signal Harness for Gen 3 FJR1300
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<blockquote data-quote="richardsutton" data-source="post: 1461681" data-attributes="member: 99925"><p>An update with more photos.</p><p>Firstly, I would echo FishinVA's comments. I have pinned and de-pinned many auto connectors over the last 50 years but I have never done a connector as difficult as this Sumitomo one. The pins are very small and are a very close fit in the housing. I do not have the correct crimping tool for these pins so I soldered the wires into and pin and then crimped it with needle-nosed pliers. The clearances are so tight that if you have a tiny bit too much solder you will not be able to insert the pin. You basically need just the thinnest wipe of solder on the pin, just enough to grip the conductor, but so little that you can still bend the crimp tabs over.</p><p>I have succeeded in the end but my advice would be to buy the correct crimper which folds the two metal flaps inwards and try to avoid soldering unless you have a very light touch and a very hot fine point soldering iron.</p><p>I also purchased the purple seals but these are too small for 1.7mm diameter cable. I did manage to get them on but it is not very neat so buy a larger size.</p><p>I definitely will not be making any more as the number of hours I've spent on this would never be cost effective.</p><p>I have wired all the pass-through connectors in black and then used the STS/ST2 colours (blue, yellow and green) for the indicator connectors as these are the colours which are used for the bike side of the ST2. I've also used the same colours for the handlebar side as I didn't have any more colours apart from red which I will use for the 12V +ve if I need to.</p><p>I've attached photos showing the ST2 placement and where the ST2 cables enter into the nose cone.</p><p>Tomorrow will finally be installation and testing!</p></blockquote><p></p>
[QUOTE="richardsutton, post: 1461681, member: 99925"] An update with more photos. Firstly, I would echo FishinVA's comments. I have pinned and de-pinned many auto connectors over the last 50 years but I have never done a connector as difficult as this Sumitomo one. The pins are very small and are a very close fit in the housing. I do not have the correct crimping tool for these pins so I soldered the wires into and pin and then crimped it with needle-nosed pliers. The clearances are so tight that if you have a tiny bit too much solder you will not be able to insert the pin. You basically need just the thinnest wipe of solder on the pin, just enough to grip the conductor, but so little that you can still bend the crimp tabs over. I have succeeded in the end but my advice would be to buy the correct crimper which folds the two metal flaps inwards and try to avoid soldering unless you have a very light touch and a very hot fine point soldering iron. I also purchased the purple seals but these are too small for 1.7mm diameter cable. I did manage to get them on but it is not very neat so buy a larger size. I definitely will not be making any more as the number of hours I've spent on this would never be cost effective. I have wired all the pass-through connectors in black and then used the STS/ST2 colours (blue, yellow and green) for the indicator connectors as these are the colours which are used for the bike side of the ST2. I've also used the same colours for the handlebar side as I didn't have any more colours apart from red which I will use for the 12V +ve if I need to. I've attached photos showing the ST2 placement and where the ST2 cables enter into the nose cone. Tomorrow will finally be installation and testing! [/QUOTE]
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FJR Motorcycle Forums
Technical & Mechanical Problems
STS Turn Signal Harness for Gen 3 FJR1300
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