Devon TRF Group Forum

Big T · Expert

Waterproof connectors & Electircal stuff.

RichT4 · Champion

Big T wrote:
1) What would you recommend as conncetors for wiring up the lighting etc. on my CRF. I have plenty of crimp-type bullet connectors, but these are not waterproof and I'd like soldered connectors. I want to retain the ability to disconnect bits when I need to. Many of you have done resto's and replaced wiring looms etc, so what would you suggest.
I would go with the crimps as solder joints will be very prone to curroding and breaking due to the vibration (and wiggling of the wires). I have some solder joints on my head light but I have strong strain relief set up and have sealed the joints in silicon sealant. Crimps don't mind the water as much as you'd think but you could fit all you connections into a water proof box - I think gaschef did that and it looks very neat.
2) I'll need a handful of different coloured bits of wire to join all this up without confusion - can I buy a selection of e.g. 1m lengths, or would I be as well to get an old (not too old) loom of a breaker, and use this instead.
I use a lot of recycled wire, just make sure it's thick enough to carry the current and it hasn't spend it's life wiggling or flexing or many of the individual wires that make up the cable could be broken.
3) Currently, rear light runs off DC (battery) and front light runs off AC (generator). If I make the lights switchable, I'll need to combine them both onto DC. Should I leave them always-on instead, and just switch the headlight high/low? Certainly simpler to wire up.
I like it to be switcheable so you have the option, the lighting circuit may develop a fault while your out - you can switch it off if it's on a switch..
4) Any recommendations for a key-switch? This would add security as well as properly disconnecting the battery when the bike is left.
ebay
... there may well be more questions to follow ...

TTR · Powermonger!!

I like block connectors as they look at home on a bike loom. However crimped bullet connectors are a good alternative as long as you use the "Japanese" type with the clear plastic sleeves rather than the car-type red and blue variety.

I used to use old looms but the copper was often black with corrosion. I eventually succombed and bought some rolls of wire from Wiring Products of the most common colours.

Nige · Expert

Cg125 switch gear is good quality with the right functions and comes with bullets.
Use the DC to switch relays that output the AC for the headlights this will keep the load off the rectfier.

As for waterproof use a decent dewatering spray.