Recommendations for quality electrical connectors and crimping tool in the UK

[HondaCB200Lady]

We are currently fitting a NOS wiring harness to Olive, my Honda CB200. As some of the connecting wires have been replaced with modern connectors, we are wanting recommendations for good quality bullet (male/female/double), spade connectors, covers and crimping tool in the UK. Had a look on eBay and they all look similar, so would prefer to hear from people who have found ones that they are happy with.

I believe that the size is 3.9mm, but if anyone knows if this is accurate or not, please let me know.

Will be having fun with what we call 'Spaghetti Junction' in the headlamp!

 

[HondaCB200Lady]

Another quick question, I notice that some connectors are brass and others silver coloured, is there a reason for the differences and do they need to be matched, like for like?

 

[Talisman]

It looks very familiar ))) Lots of fun with replacement sealed headlight unit on my CL175. On the topic please take a look at www.shiresbike.co.uk. They have various types of connectors including block wiring loom harness connector plugs . See picture.

​

 

[HondaCB200Lady]

Thanks Talisman, I'll have a look. Don't really want to change the headlight, trying to keep as many original parts or NOS as possible.

 

[Talisman]

Thanks Talisman, I'll have a look. Don't really want to change the headlight, trying to keep as many original parts or NOS as possible.

I changed headlight (original part) only because the bulb in sealed unit has gone. In terms of electric harness and electric parts I'm not so fussy. Lots of staff is impossible to get so I'm using alternative parts to keep going, where other original parts are not available. E.g. Turing signals relay. I found one on e-bay which in description said relay for Land Rover... It fits perfectly and works well on my bike

 

[Richard Pitman]

I got all the parts I needed to build a new loom from Kojaycat. He has all the bits, including the rare 5 way female bullet connectors. He also does a reasonably priced crimping tool, not a ratchet one, but entirely usable. All Honda wiring colours in stock.

950000457

Automotive and motorcycle 12v 24v electrical connector plugs, UK made thin wall harness cable and colour wiring diagrams

kojaycat.co.uk

Sprung Crimping Tool For Motorcycle Non-Insulated Terminal N-3

Crimping tool suitable for use on Japanese 3.9mm, 4.8mm and 6.3mm motorcycle terminals and some other non insulated connectors.

kojaycat.co.uk

One 3.5mm Japanese 5 Way Tinned Brass Socket L-21

One 5 way tinned brass Japanese 3.5mm motorcycle wiring socket terminal plus 4 bullets for use on electrical looms.

kojaycat.co.uk

 

[Richard Pitman]

For flasher relays, I use this type. They work with both incandescent and LED bulbs, or a mixture of both. Cheap as chips and reliable, all four of my bikes use this type of relay.

 

[Talisman]

For flasher relays, I use this type. They work with both incandescent and LED bulbs, or a mixture of both. Cheap as chips and reliable, all four of my bikes use this type of relay.

View attachment 24597

Thank you for sharing. For my CL175 I specifically looked for three pin relay, as close as possible to original one.

 

[Richard Pitman]

Thermally operated essentially means that it is the older mechanical type of relay, and wouldn't work properly ( it'd flash too fast) if low load lamps like LEDs were in use. 3 pins ? - I thought that the OEM part was only 2 pins, same as the electronic ones I posted about.

However, I now see that the CL175KO uses this part:


And the later CL175 (and CB200) use this part, without the separate ground lead. In fact, the later part is rubber mounted, so obviously doesn't need to be grounded, just power in, flash out, to put it crudely. I'm sure the later part would work in the K0 circuit though.

 

[Talisman]

Thermally operated essentially means that it is the older mechanical type of relay, and wouldn't work properly ( it'd flash too fast) if low load lamps like LEDs were in use. 3 pins ? - I thought that the OEM part was only 2 pins, same as the electronic ones I posted about.

However, I now see that the CL175KO uses this part:

View attachment 24601
And the later CL175 (and CB200) use this part, without the separate ground lead. In fact, the later part is rubber mounted, so obviously doesn't need to be grounded, just power in, flash out, to put it crudely. I'm sure the later part would work in the K0 circuit though.
View attachment 24602

You are right again. That both types of relay are shown on CMS website are correct, particularly first version. However when fixing problem with turn signals on my CL175 I noted a three pin unit neatly bolted to the frame. Considering a one for one replacement, I was looking on e-bay for similar unit.

 

[fxray]

I have bought from these vendors, with good results:

Sparckmoto owned by Sonreir, a member on this site.

Vintage Connections also owned by Sonreir.

British Wiring an excellent source for color coded wire

 

[HondaCB200Lady]

I got all the parts I needed to build a new loom from Kojaycat. He has all the bits, including the rare 5 way female bullet connectors. He also does a reasonably priced crimping tool, not a ratchet one, but entirely usable. All Honda wiring colours in stock.

950000457

Automotive and motorcycle 12v 24v electrical connector plugs, UK made thin wall harness cable and colour wiring diagrams

kojaycat.co.uk

Sprung Crimping Tool For Motorcycle Non-Insulated Terminal N-3

Crimping tool suitable for use on Japanese 3.9mm, 4.8mm and 6.3mm motorcycle terminals and some other non insulated connectors.

kojaycat.co.uk

One 3.5mm Japanese 5 Way Tinned Brass Socket L-21

One 5 way tinned brass Japanese 3.5mm motorcycle wiring socket terminal plus 4 bullets for use on electrical looms.

kojaycat.co.uk

Do you know which are the Honda wiring sizes/colours Richard? I have had a look and don't know where to start.

 

[LongDistanceRider]

I'm pretty sure your connectors are 3.5mm, not 4mm.

 

[Richard Pitman]

Do you know which are the Honda wiring sizes/colours Richard? I have had a look and don't know where to start.

Apologies for not responding sooner. I've just been looking at Kojaycat site and can't find the cables that I bought either. I do wonder if Colin is winding down somewhat. So, I checked my various purchase histories and found that the last time I bought cable here was back in 2018. I did buy a load of connectors from him last January, but no wire in that order. It then dawned on me that I'd not been able to find the cable I wanted at that time either.

What you need is Thin Wall 1.0mm diam 16.5 amp Tracer Cable.

I got my last batch from Choice Cables, all colours and permutations available on this link, not just black and white,

EDIT Even this site is hard to navigate. Once in their shop, enter 'tracer' in the shop search box. You'll then get a list of base colour cables and coloured traces eg yellow wire with choice of red, green etc etc trace colours. Before starting my order, I wrote down a list of all the cable colours I needed from the wiring diagram in the handbook, then ticked them off as I located them. Usually, 1 meter of each is ample, possibly 2 meters for some of the wires, helps to have a scrap loom to take measurements from.

1.0MM AUTO CABLE, 12/24V THINWALL BLACK TRACER STRIPED CAR BOAT WIRE 16.5 AMP | eBay UK

1mm AUTO THINWALL SINGLE CORE CABLE. YOU CHOOSE COLOURS AND. OVER 100 TRACER STRIPED COLOURS AVAILABLE. Quality thin wall 1mm 32st/0.2 16.5 amp auto cable. Simply select your desired colour and length from the drop down list above.

www.ebay.co.uk

 

[Richard Pitman]

3.5mm bullet connectors are the ones you need. I mistakenly bought the 3.9 connectors when I got my first 175, and they were too large to fit the existing connectors. Pity, because the 3.9 parts are far more sturdy than the 3.5 ones. For the cable I'd go for stranded rather than the single conductor wire which is in some of the adverts on Amazon.

 

[HondaCB200Lady]

3.5mm bullet connectors are the ones you need. I mistakenly bought the 3.9 connectors when I got my first 175, and they were too large to fit the existing connectors. Pity, because the 3.9 parts are far more sturdy than the 3.5 ones. For the cable I'd go for stranded rather than the single conductor wire which is in some of the adverts on Amazon.

Thanks Richard, it is a minefield sometimes, trying to get the right parts. I am tempted to use some of the old harness, the cables were mainly good, it had just been patched up in a couple of places.

New harness is fitted now and everything is working, just need to make new horn connection and one for the Regulator.

 

[Richard Pitman]

Just in case anyone is still following this thread and interested in a UK supplier of electrical stuff, specifically cable for making up Honda wiring looms.

I have to confess to having had yet another 'senior moment'. I've just found the invoice for my last order of thin wall Honda colour coded cable. Pretty scary that I had completely forgotten about this supplier.

It came from these folks :

Welcome to Auto Electric Supplies - Auto Electric Supplies Website

AES are the leading suppliers of auto electrical components and accessories for modern and classic vehicles. Marine and boat electrical parts also supplied. If you are wiring or rewiring a vehicle, shop online or download a free AES catalogue and buy via mail order. We also have a French Website...

www.autoelectricsupplies.co.uk

Who, oddly enough, are based just a short distance away from me, on one of my favourite riding routes - Worcester > Bromyard > Tenbury > Great Witley > Holt Fleet > Worcester.