Adventure Barbecue Averted - Now where can I get this connector?

Yardstick · 05-13-2011, 06:11 PM

Doing some maintenance I noticed a little aneurysm on my Regulator/Rectifier connector. Thinking it odd I tried to separate the connector, but it was fused! I hadn't noticed any charging issues before this (no battery whistle or dead battery after sitting). It's a little too far from running condition to check now too. I think I'll at least replace the RR, but I would like to keep from cutting up the connector on a new unit. Anyone know where I can find the mating connector on the stator side (assuming I don't have to buy a whole stator!)?

Sacal · 05-13-2011, 06:52 PM

Try Eastern Beaver!

http://www.easternbeaver.com/Main/El...onnectors.html

I got a couple of tiny three way fuse blocks and some other hard to find connectors from him a few months ago. Quick delivery and good service....drop him an email if you don't see what you need, he can source most connectors for bikes.

No affiliation, just a happy customer!

jamesbrown · 05-13-2011, 07:03 PM

Do you think that was from being crudded up? That connector is a crap magnet, but yours looks pretty clean...

Yardstick · 05-13-2011, 07:26 PM

Thanks for the link Sacal. I'll try them if I find the stator is still good.

The connector looks clean because I cleaned it.

I'm not sure what the root cause is yet. Something sure caused a lot of heat generation in there. The bike has 37,000 miles on it, so it could just be a combination of old wire, crap in the connector, high loads (two 90W heated vests + other accessories & HID's firing up?) or who knows... I don't want to rule anything out completely yet.

Garp · 05-14-2011, 03:22 AM

Do a Google search for Aprilia Brown Connector, they ae notorius for cooking these parts. General solution seems to be to dump the connector and hard wire.

cagiva549 · 05-14-2011, 04:54 AM

Cut it out and connect the wires permanently , cut as close to the burnt connector as close as possible because each time you want to disconnect you will loose some more wire . When one component fails order new connectors with the new component . SEYA

Yardstick · 05-14-2011, 08:48 AM

I was thinking last night about hard wiring it! It's good to know I'm not the only one who came up with that solution.

Now the question is: Crimp connector with integrated adhesive lined shrink tube, or Solder and use adhesive lined shrink tube?

Those Aprilia connectors are the exact same thing having the exact same problem. It looks like they stay a lot cleaner, so the failure is probably not related to the build-up of crap that the KTM connector gets. Now I'm wondering if part of the problem of Super Enduros eating RR's is that plug.

6732cash · 05-14-2011, 11:01 AM

Quote:

Originally Posted by Yardstick

I was thinking last night about hard wiring it! It's good to know I'm not the only one who came up with that solution.

Now the question is: Crimp connector with integrated adhesive lined shrink tube, or Solder and use adhesive lined shrink tube?

Those Aprilia connectors are the exact same thing having the exact same problem. It looks like they stay a lot cleaner, so the failure is probably not related to the build-up of crap that the KTM connector gets. Now I'm wondering if part of the problem of Super Enduros eating RR's is that plug.

solder and heat srink

triplenickel · 05-14-2011, 11:27 AM

Quote:

Originally Posted by 6732cash

solder and heat srink

Absolutely 100% no question solder!

KTMSER · 05-14-2011, 11:41 AM

Never had a problem with the connectors on the four VR's I have had to replace.. On my fifth VR..
I used dielectric grease from day one with no connector issues.

Dirty loose connection's generate heat leading to melting & burning..

1stiski · 05-15-2011, 08:29 AM

WOW , thats a clean connector, mine is covered with residue oil from sloppy oil changes, I figure it keeps the connector corosion free.. Im wondering what would of caused that type overload in that plug, enough to cook the plastic?

Yardstick · 05-17-2011, 10:25 PM

That was a connector sprayed down with brake cleaner to remove the build-up of oil and dirt. If yours is covered in crap it would be a good idea to clean and inspect it before you end up with a toasty sensation on your left toes.

According to some Electrical Engineering friends, for a permanent connection, both crimping and solder are the way to go! Crimping makes a better mechanical connection and solder is a better electrical connection. I took the metal crimp parts out of some crimp type butt-splice connectors and crimped those on. Then soldered and heat shrunk the whole thing in adhesive lined shrink tube. That fooker's REALLY connected now.

charlie264 · 05-18-2011, 05:00 AM

Make sure you've got a clean earth to the rectifier, ie where it bolts on.

Teeblatt · 10-12-2012, 08:30 PM

I think I've tracked down this connector, but have not confirmed the dimensions. The plug appears to be a Sumitomo HD Series 305 P/N# 6098-0208 Male and P/N# 6098-0210 female.

If anyone is in the know on this plug, please let me know, is this right connector and is there a source for small quantities.

Any help would be greatly appreciated.

Pic of the terminals.

Pic of the connector body

Sumitomo HD Series catalog
http://www.sws.co.jp/en/product/conn...pdf/nwp_hd.pdf

Head2Wind · 10-12-2012, 10:28 PM

Quote:

Originally Posted by charlie264

Make sure you've got a clean earth to the rectifier, ie where it bolts on.

FYI, I don't believe that this rectifier requires a GND (earth) and as mounted in the OEM configuration, the whole assembly that holds all this stuff is the battery box which is plastic....

05-13-2011, 06:11 PM	#1
Yardstick ^OP Hydrophobic Joined: Oct 2007 Location: Chandler, Arizona Oddometer: 2,400	Adventure Barbecue Averted - Now where can I get this connector? Doing some maintenance I noticed a little aneurysm on my Regulator/Rectifier connector. Thinking it odd I tried to separate the connector, but it was fused! I hadn't noticed any charging issues before this (no battery whistle or dead battery after sitting). It's a little too far from running condition to check now too. I think I'll at least replace the RR, but I would like to keep from cutting up the connector on a new unit. Anyone know where I can find the mating connector on the stator side (assuming I don't have to buy a whole stator!)? __________________ 2011 KTM 990 Adventure R 2010 KTM 530 EXC 2009 KTM 950 Super Enduro Erzberg Edition

05-13-2011, 06:52 PM	#2
Sacal Gnarly Adventurer Joined: Jun 2010 Location: London, England Oddometer: 119	Try Eastern Beaver! http://www.easternbeaver.com/Main/El...onnectors.html I got a couple of tiny three way fuse blocks and some other hard to find connectors from him a few months ago. Quick delivery and good service....drop him an email if you don't see what you need, he can source most connectors for bikes. No affiliation, just a happy customer! __________________ ad astra per alia porci

05-13-2011, 07:26 PM	#4
Yardstick ^OP Hydrophobic Joined: Oct 2007 Location: Chandler, Arizona Oddometer: 2,400	Thanks for the link Sacal. I'll try them if I find the stator is still good. The connector looks clean because I cleaned it. I'm not sure what the root cause is yet. Something sure caused a lot of heat generation in there. The bike has 37,000 miles on it, so it could just be a combination of old wire, crap in the connector, high loads (two 90W heated vests + other accessories & HID's firing up?) or who knows... I don't want to rule anything out completely yet. __________________ 2011 KTM 990 Adventure R 2010 KTM 530 EXC 2009 KTM 950 Super Enduro Erzberg Edition Yardstick screwed with this post 05-13-2011 at 07:35 PM

05-14-2011, 03:22 AM	#5
Garp Beastly Adventurer Joined: Apr 2003 Location: CT Oddometer: 1,642	Do a Google search for Aprilia Brown Connector, they ae notorius for cooking these parts. General solution seems to be to dump the connector and hard wire. __________________ Far better is it to dare mighty things, to win glorious triumphs, even though checkered by failure... than to rank with those poor spirits who neither enjoy nor suffer much, because they live in a gray twilight that knows not victory nor defeat. - Theodore Roosevelt

05-14-2011, 04:54 AM	#6
cagiva549 whats a cagiva Joined: Oct 2004 Location: Cypress Tx Oddometer: 2,454	Cut it out and connect the wires permanently , cut as close to the burnt connector as close as possible because each time you want to disconnect you will loose some more wire . When one component fails order new connectors with the new component . SEYA __________________ David H 00 Cagiva GC 04 9 fiddy 05 ST3 duck 07 KTM 450 EXC 86 Goldwing my geezer ride

05-13-2011, 07:03 PM	#3
jamesbrown Lefty tighty. Joined: Nov 2007 Location: Gone Oddometer: 6,413	Do you think that was from being crudded up? That connector is a crap magnet, but yours looks pretty clean...

05-14-2011, 08:48 AM	#7
Yardstick ^OP Hydrophobic Joined: Oct 2007 Location: Chandler, Arizona Oddometer: 2,400	I was thinking last night about hard wiring it! It's good to know I'm not the only one who came up with that solution. Now the question is: Crimp connector with integrated adhesive lined shrink tube, or Solder and use adhesive lined shrink tube? Those Aprilia connectors are the exact same thing having the exact same problem. It looks like they stay a lot cleaner, so the failure is probably not related to the build-up of crap that the KTM connector gets. Now I'm wondering if part of the problem of Super Enduros eating RR's is that plug. __________________ 2011 KTM 990 Adventure R 2010 KTM 530 EXC 2009 KTM 950 Super Enduro Erzberg Edition

05-15-2011, 08:29 AM	#11
1stiski Ride that nasty thing Joined: Oct 2003 Location: Elizabethville, PA Oddometer: 1,425	WOW , thats a clean connector, mine is covered with residue oil from sloppy oil changes, I figure it keeps the connector corosion free.. Im wondering what would of caused that type overload in that plug, enough to cook the plastic? __________________ "04" 950 Adventure S 34,000+ miles Smokin Hole Rally 1,2,3,4,5,6...upcoming 7 Cromag 05, 08. "The Grim Brothers" Where's my 690 rally replica

05-17-2011, 10:25 PM	#12
Yardstick ^OP Hydrophobic Joined: Oct 2007 Location: Chandler, Arizona Oddometer: 2,400	That was a connector sprayed down with brake cleaner to remove the build-up of oil and dirt. If yours is covered in crap it would be a good idea to clean and inspect it before you end up with a toasty sensation on your left toes. According to some Electrical Engineering friends, for a permanent connection, both crimping and solder are the way to go! Crimping makes a better mechanical connection and solder is a better electrical connection. I took the metal crimp parts out of some crimp type butt-splice connectors and crimped those on. Then soldered and heat shrunk the whole thing in adhesive lined shrink tube. That fooker's REALLY connected now. __________________ 2011 KTM 990 Adventure R 2010 KTM 530 EXC 2009 KTM 950 Super Enduro Erzberg Edition

05-18-2011, 05:00 AM	#13
charlie264 Beastly Adventurer Joined: Oct 2007 Location: Blighty Oddometer: 5,004	Make sure you've got a clean earth to the rectifier, ie where it bolts on. __________________ Beauty is truth and truth is beauty. Charlie's Side Stand Relocator.

10-12-2012, 08:30 PM	#14
Teeblatt Stoichiometric Bliss Joined: Jul 2009 Location: Jacksonville, FL Oddometer: 69	Not Confirmed, but I think I kow what this connector is. I think I've tracked down this connector, but have not confirmed the dimensions. The plug appears to be a Sumitomo HD Series 305 P/N# 6098-0208 Male and P/N# 6098-0210 female. If anyone is in the know on this plug, please let me know, is this right connector and is there a source for small quantities. Any help would be greatly appreciated. Pic of the terminals. Pic of the connector body Sumitomo HD Series catalog http://www.sws.co.jp/en/product/conn...pdf/nwp_hd.pdf __________________ 2008 KTM 990 Adventure Black 2007 KTM 640 Adventure

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