Convert died, had to be trailered home

[bigbikerrick]

Hello Folks, I took the convert for a ride last night,and as I turned into a gas station, it just died. I coasted to the pump, and filled the bike up, as I had switched to reserve. When I went to start the bike, I hit the start button, and nothing, not a click or anything. I had headlight , horn, etc. The battery was showing green light on the kuryakin meter,so I knew it was not the battery. It was 11 O clock at night, I was tired, and about 8 mlies from home. I called my son,and he came out with a trailer,and we hauled the bike home. Today I started looking into the failure, and started by taking out the battery, removing the fuel tank, and the hard to get to starter relay, behind the rear brake master cylinder.then after all this searching,I  found the 3 wire connector that plugs in to the back of the headlight bucket,on the right side, had come  disconnected.ARRRRG GGHHHH!!    Oh well, I feel kinda stupid, as this happened one time before, and I just pushed it back in, without doing anything about preventing future problems.  Live and learn! 
Rick D.

[wirespokes]

Glad it wasn't the Dyna!

[bmc5733946]

I frequently run a zip tie through the wires and around those molex plugs to secure them together. I know that's probably not possible with the plugs in the headlight shell but I might modify something to make it happen. Good luck!

Brian

[blackcat]

I frequently run a zip tie through the wires and around those molex plugs to secure them together.

Brian

Yep, I do the same thing with those connectors.

[Chuck in Indiana]

That makes 3 of us. 

[Tom H]

Glad it wasn't the Dyna!

My first thought when I read the header was that it died. Glad it was something else!!!!

Tom

[bigbikerrick]

Well, guys, since I had  recently installed the Dyna ignition, and the bike died suddenly, that was my first suspicion... I always think back to the last thing I changed, or tinkered with as the suspect, but I am happy to report, the electronic ignition is working great!  I plan to add small zip ties to keep the connector together, as there is some "pull" on it when the bars are turned.I am thinking 2 small holes drilled in the headlight shell, adjacent to the  rectangular opening for the molex plugs would work to run a small zip tie through to secure the plugs.
Rick.

[fotoguzzi]

Could you use a twist tie instead and would that fit thru the plug opening?

[bigbikerrick]

Great minds think alike, Foto! I started running a piece of wire from a wire feed mig, passing it along the sides of the rectangular opening in the headlight bucket, but it was a bit too thick to fit between the terminal and opening, so I backed off, thinking it may contact one of the terminals. I was going to twist it inside the headlight bucket, cutting off the ends as needed.  A wire tie , like you recommend would surely be easier to work with since its not as stiff, or as thick, as the welding wire. Your idea is a better one.
 I need to go back in there and secure not just the 3 wire terminal that unplugged, but the bigger  multi wire one next to it also. I have a "Jeep" led headlight unit coming in, that I plan to install in the convert. It should arrive in a day or two, so I will be doing that adaptation into the stock headlight,and securing both wiring connectors.
  Right now the Convert is running so good, and the riding weather is so nice here in the high desert, that I have riding it every day, every chance I get, putting on as many miles as possible.
Rick D.

[Antietam Classic Cycle]

Great minds think alike, Foto! I started running a piece of wire from a wire feed mig, passing it along the sides of the rectangular opening in the headlight bucket, but it was a bit too thick to fit between the terminal and opening, so I backed off, thinking it may contact one of the terminals. I was going to twist it inside the headlight bucket, cutting off the ends as needed.  A wire tie , like you recommend would surely be easier to work with since its not as stiff, or as thick, as the welding wire. Your idea is a better one.
 I need to go back in there and secure not just the 3 wire terminal that unplugged, but the bigger  multi wire one next to it also. I have a "Jeep" led headlight unit coming in, that I plan to install in the convert. It should arrive in a day or two, so I will be doing that adaptation into the stock headlight,and securing both wiring connectors.
  Right now the Convert is running so good, and the riding weather is so nice here in the high desert, that I have riding it every day, every chance I get, putting on as many miles as possible.
Rick D.

There's at least one empty hole in the larger multi-pin connector, a screw can be inserted through that hole and secured with a nut. I think Greg Bender told me about that.

[bigbikerrick]

Thats clever, Charlie. I would never have thought about that. must be a teeny weeny little bolt!   
Rick

[TOMB]

I don't remember the year of your Convert but here goes.

I own a 76 Convert and I was having issue with the start button and kill switch.

Hard to start, no ignition ---here is all of the wires for the right switch are inside the handlebar and the wires had chaffed causing you guessed it ISSUES.

Bypassed the wires inside the handlebars to the outside, I connected the two wires together inside the headlight shell, the remaining wire is for the starter.

If you put the two white wires / black stripe that's the kill switch together no more kill switch. But in my case, it works for the result I was looking for.

Might cure your problems.

TOMB

[bigbikerrick]

Thank you, Tomb. I had replaced the sketchy oem start stop switch , with an aftermarket one MG cycle sells, when I first got the bike a year ago. I also ran the wires outside the handlebars. My whole problem apparently was the connector on the headlight shell, coming partially unplugged as the bars were turned.
Rick.