While maneuvering the bike out of the garage I managed to knock the mirror/turn signal pod off it's bracket.  The lanyard kept it from crashing to the floor but I had made the lanyard too long and the turn signal wires pulled out.  Unfortunately, the wires pulled out of the plug rather than the male and female pieces coming apart. So now I have the problem of trying to put the wires back into the plug, something that it's not designed to do.  I was thinking of heating up the wires with a bit of solder on them and pushing them into the socket but I'm afraid that it may melt the plastic.  The plug won't pry open and I can't get at the metal crimps on the inside.  Any suggestions? 





Thanks

1989 BMW K100RS Special Edition

Bit of bad luck there, but at least you saved the mirror. 

Looks like the wires were on the verge of breaking anyway, possibly had water ingress over time and things have just rotted and weakened...the drop was just the final straw. Normally, the wires would easily take the weight of the mirror and the connector would part first.

I don't think that you will have much success with trying to solder the wires back into the socket. If you don't have a spare plug (I don't know if they are still available), then I would be tempted to cut it off and replace with bullet type connectors (available from most auto stores). That way you are still able to separate the wires if required to remove the mirror.

If you want to keep it authentic Nvboy I'd try the wreckers for a BWM car and see if any connectors can be liberated off one, But I'd also have a go at reusing that black connector case again, with the nice little Jap bullet connectors (the ones shown above) in it.

I think you might find the connectors in the bmw plastic are about 2.1mm
where as the bullit connectors shown are about 3  ...3.5 mm diameter the Japanese standard ...and closer to 4mm as an accessories supply

no matter for the wiring ...or current demands either way ,,,just harder to find in this day and age

remember to use the socket parts for the wiring feed to the indicators ...( insulated from shorting out )   the plug part should fit on the indicator end

Maybe the Jap Bike connectors may be small enough out of early 80's bikes

BAE - I hate those pre-insulated crimp bullet connectors with a loathing you wouldn't believe. It's almost impossible to get a clean crimp on them with the tool that's sold as 'suitable' - it's anything but.

NVBoy - what I've done on four K's now is to remove the plug from the pod, cut it off, extend the wires with new sections and then crimp on 'Japanese' (3.9mm) non-insulated bullets (with the required insulating sleeves). This type:

http://www.vehicle-wiring-products.eu/section.php/175/1/japanese-motorcycle-bullet-socket-connectors

That said, Molex do a similar two-way plug that fits right into the BMW socket. This is the stuff on the Farnell Element 14 website that I have used to replace the BMW OEM sockets when necessary:

Socket: http://uk.farnell.com/molex/3061022/housing-receptacle-2-way-nylon/dp/1079891
Female pins: http://uk.farnell.com/molex/02-06-1103/crimp-socket-18-24awg/dp/1079889

The other side just in case you ever need it:

Plug: http://uk.farnell.com/molex/03-06-2023/housing-multipole-plug-2way-nylon/dp/1462870
Male pins: http://uk.farnell.com/molex/02-06-2103/contact-pin-24awg-to-18awg-crimp/dp/1079887

Farnell are a global company, so ignore the 'uk.' - just select your own country or edit the link to add your own country's header. If you loose the links by changing the country, I've highlighted the search terms you'll need. The minimum buy quantities are listed next to each item. You'll also need to cut the ears off the sockets because they're designed to be panel-mounted. BUT: you're left with the problem of finding a suitable crimp tool - mine is over thirty years old and you can't have it! If you're a dab hand with a soldering iron then you could take that route.

Would guess that the easiest way out is to buy the OEM parts.
Contact housing, part # 61 13 1 369 229.
Contact(s), part # 61 13 1 371 607.

It's also the same connector as used on the brake light and clutch switches.

Paul.

I've had a couple of goes at trying to rewire and salvage the old plug.  I've tried to dig the old broken wire out of the crimp with a needle and then push in a new wire with still-hot solder but no go.  Is there a conductive moldable metal to cement the wires in?

Regardless, I've ordered some new OEM plugs from BikeBandit.  How does wiring those work?  Is there a crimp plug that you crush the wire in then jam the crimp part into the plastic plug?  I'm trying to keep the bike original but if all else fails I'll splice in a new modern plug into the turn signal, but's tight maneuvering in there with a very short wire.  Hoping I can pull the plug socket out to make life easier.

thanks

nvboy wrote: How does wiring those work?  Is there a crimp plug that you crush the wire in then jam the crimp part into the plastic plug?

The contacts have small lock tabs that spread out wider than the contact body.
You first crimp the wire and the contact together, then you push the contact
into the plastic housing from the rear side untill you feel the lock tabs clicks
in place into the groves inside the housing.

The tool to remove the contacts from the housing is a very thin walled metal
tube which you push into the housing from the front, this metal tube forces
the lock tabs towards the center of the contact so they lose the grip in the grove.

I also knocked the mirror pod off of my riding bike and had one of the wires break at the end of the female socket connection point (just today). As well I have a slow rebuild underway that will need at least one or two new female socket assemblies.
Went to bike bandit and one other site for the parts only to find that it will cost about seven dollars Canadian for each of the contacts plus twenty to thirty dollars for shipping to Canada. The cost of the housing is insignificant but the contacts are pricey. Four contacts plus shipping at 60 Canadian dollars seems ridiculous or perhaps I am just being too cheap. 
Nvboy I was wondering  if you were able to get the shipping at a cheaper rate or get a better price on the contacts.
In the meantime I am trying to chase down a Canadian Molex source.

Shep

Shep - the site you want is canada.newark.com. Just enter the search terms I've highlighted.

Shep - I'm on the Island but I make occasional business trips to the mainland and maintain an American mailbox just over the border.  American businesses often offer free shipping within the States so I just time my orders with my trips to the mainland.  Bit difficult for you in PG.  I ordered and received the OEM plugs but neglected to order the metal crimpers on my last recent trip.  Fume.
Sourcing them now with the help of the forum.

nvboy

Q:  What's in a Nanaimo bar?
A:  Strippers and Hell's Angels.

Here in Oz we can buy a Molex 2 pole connector from a local Jaycar electronics franchise in just about every largish town. Even our SuperCheap Auto accessories franchise has these or something very similar. They're about $2.75

If you can't find an automotive/electronics parts retailer in your area, try this
Molex distributors in North America

Any time I need to replace a connector on my bikes I use Deutch connectors.

I too have a hate-hate relationship w/the preinsulated bullet connectors - having tried to use a heat gun before and after crimping to try and get them to work..