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Discussion Starter #1
Has anyone done a repair on a Molex connector??
I have a broken wire on the TCA plug so I need to re-pin the broken wire to get the bike running.
What I really need to do is re-pin all 6 of the pins in the TCA plug so all the wires are the same length.
I can get the new pins and if needed I can get the new housing which I don't need but I may put a new one on anyways but I don't have the Molex pin crimping tool.
Does anyone know where to get one of the crimping tools besides online because I don't want to wait for the tool to be shipped?
Is there another crimping tool that would work besides the Molex crimping tool?
 

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Sears, radio shack, Fry's or harbor freight should all have them.
I'd hit AutoZone etc. first, sometimes they'll surprise you. They might even loan/rent you one. Check your local speed shop or any ASE mechanic. Otherwise I'd plunder around at harbor freight.
If you're really desperate and anxious you can solder those pins and bend tabs with needle nose Just don't make mess or the pin won't fit in the connector.
 

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If those places do not work, your local electronics store should have the tool. In CT there is a Signals Electronics store. Have seen several types at HD and Lowes as well. Usually have every connector and tool. Soldering can be real tricky. If the pin doesn't snap in (seen and done before) from soldering it can get pushed back when you connect it. Makes for a loose connection. Good luck.
 

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if all else fails, track down your local Snap-On franchise truck. They should have the crimpers you need. I think I paid 35-40 bucks or so. Buy extra pins because you will likely screw up the first 1 or 2 and make it unuseable.

Good luck.
 

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Discussion Starter #7
I can't find a Molex crimping tool locally. The wire is 20 or 22 gauge wire and I can find the Molex crimping tool online but they go for $100 to $400 (depending on which one I need) with most running around $250.
There are open barrel crimping tools that go pretty reasonable but I would still be spending $30 to $200 for one and I am not sure if these tools would put in the quality crimp needed for the Molex connector for the Throttle Control Actuator.
The crimp on the TCA pins are critical because the voltage at the TCA only needs to be altered by 0.13 VDC to set a DTC and put the bike in limp mode.
I guess it is off the stealership tomorrow to have the dealer do the repair because they have the right crimper to do the job, guess I will see if the extended warranty will cover this repair.
I am not sure how the wire broke but it seems to be stiff so I am would think that 7 years of engine heat & vibration may have something to do with it.
My TCA plug has never been re-pined with the 2011 pins so this is just as good of a time as any so I will have all 6 pins replaced.
 

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I can't find a Molex crimping tool locally. The wire is 20 or 22 gauge wire and I can find the Molex crimping tool online but they go for $100 to $400 (depending on which one I need) with most running around $250.
There are open barrel crimping tools that go pretty reasonable but I would still be spending $30 to $200 for one and I am not sure if these tools would put in the quality crimp needed for the Molex connector for the Throttle Control Actuator.
The crimp on the TCA pins are critical because the voltage at the TCA only needs to be altered by 0.13 VDC to set a DTC and put the bike in limp mode.
I guess it is off the stealership tomorrow to have the dealer do the repair because they have the right crimper to do the job, guess I will see if the extended warranty will cover this repair.
I am not sure how the wire broke but it seems to be stiff so I am would think that 7 years of engine heat & vibration may have something to do with it.
My TCA plug has never been re-pined with the 2011 pins so this is just as good of a time as any so I will have all 6 pins replaced.
I wouldn't worry about open or closed. A good mechanical connection is typically a good electrical connection. $23 http://www.sears.com/s-g-tool-aid-18600-open-barrel-crimping/p-SPM7423473403 Just in case they don't cover it. Get extra pins if your not happy you can re due the connection. key is follow diagram, meaning wire that is stripped should not be past the ears and you should be fine.
 

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Discussion Starter #9 (Edited)
Well I fixed my problem the old fashion way, I just soldered the wire together and put some heat shrink on the wire.
This will work until I get the crimper and do the repair the right way. ;)
 

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I found at crimper for the molex pins at an electronic/ computer supply store where the geeks literally build their own computers from scratch.

Cheap chinese knockoff but it served the purpose for the 1 time i needed it. Last time i saw it i loaned to a buddy that was changing the bars on his batwing.

Calgaryglide
 
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