Fix Your Vehicle’s Faulty Melted Connectors


 Why are my connectors melted & how can I fix them?

Got melted connectors?  Here’s why:

If connectors are not inspected & maintained, the cycle will continue and the problems will increase.

This illustrates the continuing problem of melted connectors!

Here are some examples of bad connectors that we’ve seen on customer’s parts.  If you have something that looks like this – you need to do some repair work right away!

So what can you do about it?  We’re here to help!

Step 1: Inspect

Inspect every connector whenever an electrical part is replaced. Have your connector kit, part # 11-501 ($90) on hand for repairs.

Part# 11-001 Crimper This is the same high quality crimping tool that we use for all our in-house repairs. A must-have tool for all service departments! This crimper works with all of our connector kits.


Dealing with: Corrosion

If corrosion is just starting: remove connector(s) and sand blast, wire brush, etc to clean the area.

Dealing with: Melted Plugs

If plug is melted: remove all plugs & replace them with new components using Rick’s Motorsport crimping tool – Part# 11-001 ($75)

Part# 11-501 Connector/Terminal Kit This is a general connector/ terminal kit for Import motorcycles. Contains an assortment of male & female connectors, matching terminals, and wire sleaving. See packaging for refill order information.

In some cases, terminals may need to be soldered to the wires. Depending on the degree of corrosion, some wire in the harness may need to be replaced as well. Always use a high quality/high temp dielectric grease on all electrical connections to prevent future problems.  Below is an image of what good/repaired connections should look like: