HELP! 1VJ Connector nightmare

[Ibai]

Hi there!

I´m new at this forum (recently purchased a 1987 1VJ Tenere 600) and thought maybe you could help me out with this one ...

Soooo...here´s the thing, the front headlight and some light indicators stopped working as I changed the tachometer for a functioning one, so that I tried to replace the bulb (didn´t work out) and then tried with the old tachometer again (didn´t work out either). I then checked the wiring diagram and found a wire that was connecting all the stuff that started malfunctioning. I was quite sure that while replacing the tachometer I could have cracked one of the old headlight connector wires/pins so I decided to pinch for continuity all the wires at the headlight and discovered that I my thoughts were right and that the headlight connector with the 3 headlight-bulb connections had some stuff going on. 2 of the 4 wires where cracked/broken at the very top, one of the connectors was stuck inside the plastic-plug, which resulted to be melted-stuck at that connection...
So I´m now looking for a replacement plastic-plug but can´t find one, does anybody have had this same Issue? Where do you ussually buy the electrical spares? Any alternative?? The rest of the things I need, like new connectors or spare wire is easy to find on internet so don´t care that much about that.

My english isn´t that good, so I´ll post 3 pics at the end to help me explain it. I also will be posting some photos of my own tenere .

Deceased plug on the side of the wiring connectors.

Plug on the side of the headlight-bulb.

The 3 connectors with the 4 wires (the one connector on the left has the melt of the plug)


Cheers,
Ibai.

[Mezo]

Just google it, plenty of suppliers, i searched: japanese motorcycle connectors Or search yamaha motorcycle terminal connectors

Mezo.

[motorang]

Google H4 headlight plug. It is not Yamaha specific but you want to find one with sideways connections for tight fit - the ones for cars and trucks usually are bulkier.
Every Yamaha dealer should be able to help as well, as most motorcycle or scooter shops (eg Vespa).

https://www.aliexpress.com/item/32995198553.html
https://www.ebay.com/itm/1-Pair-H4-Fema ... 2565315293

HELLA does a nice one where you can use your own cables:
HELLA 8JA 001 909-001

Andy

[Mezo]

Just a word of warning to everyone, NOTHING & i mean nothing is coming out of China (aliexpress) i have a $500 modem tied up & i doubt i`m going to ever see it (small suppliers are going bust all over China) so do not order anything from China right now.

Mezo.

[Ibai]

Thanks to you Andy and Mezo!!
I managed to get what I think is the right one.
I already have tried asking the nearest Yamaha suplier, but they are quite incompetent and wanted to sell the whole wire arness .
Jokes apart thanks for the helpful Info.

Ibai.

[Mezo]

I can see your pictures now, yep as Andy said its a H4, im guessing the lamp is to high wattage & that is how it melted?

You can buy Heavy duty Ceramic connectors. you understand the word ceramic? what cups & plates are made of.
Mezo.

[Ibai]

I´m not sure what could have happened, because the part that melted was only at 1 of the 3 conecting pins... Anyway, I see the positive side of having something to do with the Coronavirus homestaying .
Thanks for the hint of the Ceramic Mezo! Lucky enough the one I ordered by the time of the post wasn´t the cheapest one and I guess it should do the job.

Stay save,
Ibai.

[motorang]

May have melted due to bad contact (and therefore sparks/arc) or - and this may be worth checking - one of the filaments in the H4 bulb or socket is shorting to the other, so you may have up to 105W draw there (both filaments are lighting).

Andy

[Ibai]

Hi Andy, I guess it could be because of the old cables that I will be changing/reparing. Most of them were halfway broken at the conector, that means that inside the cable was only one or few wires left, while the others were broken. I guess that at the same current there was such a little diameter compared to a new cable with all wires intact, that it couldn´t withstand it and it just melt the conection.

I guess I´m replacing those and try for luck.
Until then, wish you the best.

Ibai.