Help with creating wiring harness

[stpaulscott]

I am attempting to fabricate the ignition wiring harness and have a question. Is there a good substitute method for crimping the stamped formed pins to the wires for the expensive tools? The least expensive tool I can find is $150 or so. Seems a little pricey to fold over the tabs on the pins to me. Once you have the pin connected to the wire is there a tool used to insert the pen into the connector?

Scott

[jeffthom]

StpaulScott: Please be aware that the V-Twin is the WORST environment for vibration that I have ever seen - including radial engined aircraft. Stranded wire only, of course. Remember how you can break a clothes hanger by just bending it a few times at the same place? A connector pin is that 'place' in our bikes, where the moving wire is suddenly restrained.

We need a gentle gradation from flexible part to fixed part of the wire. The proper tools create this in the pins for which they are designed. That's why soldered connections fail quickly - the abrupt change from flexible strands to the hard block of solder.

That said, I use a tool I bought several years ago for about $30. It has replaceable crimp jaws to match style and size of various 'Amp' brand (electronics usage) connector pins. I'll try to find a current, lower cost product to suggest.

Meanwhile, please find a proper tool to borrow or rent and avoid the 'mash and pray' tools. Sitting alongside the road with a mystery wiring failure really sux! --Jeff

[JohnK/Pa]

If your looking for a crimper for the pin terminals in the connectors on the bike you might be able to use this one, http://www.summitracing.com/parts/SU...1/?image=large or you could look at radio shack for a D-Sub crimper, (this is the one I have) http://www.radioshack.com/product/in...ductId=2103683, Summit also sells the pins and connectors to go with their tool.