Zongshen 200GY-A, Thar's yer problem! Starter Wires Rewire

tankme · 07-21-2014, 12:09 PM

This topic is about the starter and getting it going again. The starter wires are cut at the handlebar assembly, and what I think are the corresponding wires going to the coil are burnt. I will attach the two pics of this. I still need to hunt the wires from the handlebar cut and tucked inside tape somewhere along the main harness.

To fix I'll be re-running these wires along the main harness if my experiments connecting them directly work. Do I need to hunt a pair of actual connectors or make my own? Is there any reason not to?

Thanks!
Jim

bogieboy · 07-21-2014, 12:22 PM

you can use your own connectors... i would suggest insulated bullet style connectors... when i had to rewire my whole bike (i had a used harness to start with that needed help) thats what i used... quick, easy, clean looking.... i suggest the ones with heat shrink on the back side, as they are much more weather proof...

SpudRider · 07-21-2014, 12:41 PM

You can definitely use your own connectors.

Upon the advice of my best friend, a professional diesel mechanic with over 30 years of experience, I switched from bullet connectors to spade connectors.

I use these spade connectors for all the electrical connections on my motorcycles.

http://www.oreillyauto.com/site/c/de...ade+connectors

http://www.oreillyauto.com/site/c/de...ade+connectors

The spade connectors never loosen from the harsh vibrations induced by riding off road.

bogieboy · 07-21-2014, 12:45 PM

Quote:

Originally Posted by SpudRider

You can definitely use your own connectors.

Upon the advice of my best friend, a professional diesel mechanic with over 30 years of experience, I switched from bullet connectors to spade connectors.

I use these spade connectors for all the electrical connections on my motorcycles.

http://www.oreillyauto.com/site/c/de...ade+connectors

http://www.oreillyauto.com/site/c/de...ade+connectors

The spade connectors never loosen from the harsh vibrations induced by riding off road.

interesting... i have always had issues with spades loosening up... yet i never had issues with bullets loosening... i figured that if Honda and Suzuki thought them good enough, they would be good enough...LOL could be a case of personal experience....

SpudRider · 07-21-2014, 12:58 PM

That's funny; I have had the opposite experience.

I have had the bullet connectors loosen, but never had spade connectors loosen.

bogieboy · 07-21-2014, 01:30 PM

Quote:

Originally Posted by SpudRider

That's funny; I have had the opposite experience.

I have had the bullet connectors loosen, but never had spade connectors loosen.

interesting... perfect example i have...LOL the spade on my roketa's coil input loosened to the point of making the bike not run right, then not at all..LOL

tankme · 07-21-2014, 03:28 PM

OOo Here's a fancy one--> like this one that way no vibration issues and kind of matches the old one. $3 though.

I'm still looking around; I know there are simpler two wire auto/computer connectors by the dozen I'm not finding at the moment. On hand I do have crimp connectors of all sorts, shrink tubing and can use those if I can get away with it.

I'll report back!
Jim

Weldangrind · 07-21-2014, 09:50 PM

Excellent sleuthing! By coil wires, do you mean solenoid wires?

I rewired my old Suzuki with bullet connectors, because that's what it came with originally. it was a '77 TS185 that would vibrate your fillings loose, and the connectors never failed.

Another alternative is to build your own Molex connectors. Not too spendy, and they're quite sturdy.

tankme · 07-21-2014, 11:47 PM

Oh yes solenoid, the coil actually has all good wiring to and from.

I was rummaging through my box of computer parts and had several sets of molex connectors and went to molex.com, but I'll prolly use the regular old crimp-ons though, it is easy and no cash required. Woohoo I still haven't spent any cash!

I'll post pictures.
Jim

Weldangrind · 07-22-2014, 01:29 AM

Quote:

Originally Posted by tankme

Woohoo I still haven't spent any cash!

You and I are gonna get along well.

tankme · 07-22-2014, 05:41 PM

I think I heard "Make do, make it do, or do without"a million times growing up. It seems to have stuck as I am quite the resourceful packrat. I have a love/hate relationship with baling wire too. I'll even accept free motorcycles on the off chance I can get it to work.

Jim

Weldangrind · 07-22-2014, 09:47 PM

What you can't get to work can always be parted out or scrapped.

07-21-2014, 12:41 PM	#3
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	You can definitely use your own connectors. Upon the advice of my best friend, a professional diesel mechanic with over 30 years of experience, I switched from bullet connectors to spade connectors. I use these spade connectors for all the electrical connections on my motorcycles. http://www.oreillyauto.com/site/c/de...ade+connectors http://www.oreillyauto.com/site/c/de...ade+connectors The spade connectors never loosen from the harsh vibrations induced by riding off road. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

07-21-2014, 12:58 PM	#5
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	That's funny; I have had the opposite experience. I have had the bullet connectors loosen, but never had spade connectors loosen. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

07-21-2014, 03:28 PM	#7
tankme Join Date: Jul 2014 Location: Texas Hill Country Posts: 144	OOo Here's a fancy one--> like this one that way no vibration issues and kind of matches the old one. $3 though. I'm still looking around; I know there are simpler two wire auto/computer connectors by the dozen I'm not finding at the moment. On hand I do have crimp connectors of all sorts, shrink tubing and can use those if I can get away with it. I'll report back! Jim __________________ 2008 Zongshen 200GY-A, HS163FML : Needs: Battery, Battery Box, Both clutch and brake handles, exhaust system, all plastics, gas cap, starter rewired. Her name will be Phoenix. 2007 Shineray Speedee 150, 1P57QMJ: Needs: starter rewired, exhaust connected, cleaned up, ignition switch simplified, new seat and lights, new front and back racks. There's no such thing as a free puppy or motorcycle. I think I have caught the fever from y'all.
	0

07-21-2014, 09:50 PM	#8
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Excellent sleuthing! By coil wires, do you mean solenoid wires? I rewired my old Suzuki with bullet connectors, because that's what it came with originally. it was a '77 TS185 that would vibrate your fillings loose, and the connectors never failed. Another alternative is to build your own Molex connectors. Not too spendy, and they're quite sturdy. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

07-21-2014, 11:47 PM	#9
tankme Join Date: Jul 2014 Location: Texas Hill Country Posts: 144	Oh yes solenoid, the coil actually has all good wiring to and from. I was rummaging through my box of computer parts and had several sets of molex connectors and went to molex.com, but I'll prolly use the regular old crimp-ons though, it is easy and no cash required. Woohoo I still haven't spent any cash! I'll post pictures. Jim __________________ 2008 Zongshen 200GY-A, HS163FML : Needs: Battery, Battery Box, Both clutch and brake handles, exhaust system, all plastics, gas cap, starter rewired. Her name will be Phoenix. 2007 Shineray Speedee 150, 1P57QMJ: Needs: starter rewired, exhaust connected, cleaned up, ignition switch simplified, new seat and lights, new front and back racks. There's no such thing as a free puppy or motorcycle. I think I have caught the fever from y'all.
	0

07-21-2014, 12:22 PM	#2
bogieboy Join Date: May 2013 Location: finger lakes NY Posts: 2,046	you can use your own connectors... i would suggest insulated bullet style connectors... when i had to rewire my whole bike (i had a used harness to start with that needed help) thats what i used... quick, easy, clean looking.... i suggest the ones with heat shrink on the back side, as they are much more weather proof...
	0

07-22-2014, 05:41 PM	#11
tankme Join Date: Jul 2014 Location: Texas Hill Country Posts: 144	I think I heard "Make do, make it do, or do without"a million times growing up. It seems to have stuck as I am quite the resourceful packrat. I have a love/hate relationship with baling wire too. I'll even accept free motorcycles on the off chance I can get it to work. Jim __________________ 2008 Zongshen 200GY-A, HS163FML : Needs: Battery, Battery Box, Both clutch and brake handles, exhaust system, all plastics, gas cap, starter rewired. Her name will be Phoenix. 2007 Shineray Speedee 150, 1P57QMJ: Needs: starter rewired, exhaust connected, cleaned up, ignition switch simplified, new seat and lights, new front and back racks. There's no such thing as a free puppy or motorcycle. I think I have caught the fever from y'all.
	0

07-22-2014, 09:47 PM	#12
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	What you can't get to work can always be parted out or scrapped. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0