PC3 wiring harness plugs are coming part - 600RR.net
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post #1 of 22 (permalink) Old 10-02-2010, 09:11 PM Thread Starter
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PC3 wiring harness plugs are coming part

so i was trying to wrap up my rebuild today and i noticed that the power commander wires were not staying inside their black plugs. (the black plugs are the ones that plug into the main wiring harness on the bike)



i tried to go to pep boys and get some new connectors (the little pin things that go on the end up the cable, then go into the black plug before being plugged into the main harness) but they didn't have the correct size..

does anyone know if i can get replacement plugs with connectors from power commander? (they dont show them on their site, and when i called they were closed for the weekend)

i'm really looking for a solution of some sort, i dont want to end up having one of the wires come lose from the plug and then have an injector misfire on a cyclinder. the last thing i need is a blown motor

thanks for the help, hopefully i was clear about the problem.
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post #2 of 22 (permalink) Old 10-04-2010, 02:08 PM Thread Starter
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post #3 of 22 (permalink) Old 10-05-2010, 01:34 PM
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Quote:
Originally Posted by SuperWario89 View Post
anyone with any advice?
.

Sounds like your metal prongs got bent or somethign is jamming them.

Because it takes a LOT of force to push them out the back of the plug.
They have special metal tabs that keep them from backing out.

Double check the alignment in both plugs, and straighten them out.

ALSO, if you ruined those tabs, then put a drop of superglue on the BACK of the plug and let it dry. That should help secure the wires in there.

But, More importantly, they need to be aligned correctly.

.
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post #4 of 22 (permalink) Old 10-06-2010, 01:20 PM Thread Starter
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the metal prong is not coming out of the back of the plug... the wire got detached from the metal prong.

the metal prong is still inside the black plug, its just the wire that came out of the back.

i called Dyno jet and they couldn't tell me what size male adapter i needed to replace the prong that got detached from the wire..

does anyone know what size male adapter prong/pin goes on the end of the wire inside those small black plugs?

thank you for the help everyone
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post #5 of 22 (permalink) Old 10-06-2010, 01:24 PM
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Quote:
Originally Posted by SuperWario89 View Post
the metal prong is not coming out of the back of the plug... the wire got detached from the metal prong.

the metal prong is still inside the black plug, its just the wire that came out of the back.

i called Dyno jet and they couldn't tell me what size male adapter i needed to replace the prong that got detached from the wire..

does anyone know what size male adapter prong/pin goes on the end of the wire inside those small black plugs?

thank you for the help everyone
.

aahh.

OK. It's going to be a Big PITA to pull that metal prong from the plug and replace. You may still be better off, cleaning the wire... Stuffing it in there nice and good, and put a small drop of superglue, to keep it from coming lose.


Just an option.

.
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post #6 of 22 (permalink) Old 10-06-2010, 01:27 PM
 
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Another option is just cut the plugs off and hard wire it. No risk of loosing a connection then. How often do you remove it? Leave enough wire on a good plug so if you do remove it you can solder back a good plug and put it back to stock, then just the PC doesn't have the plug. T




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post #7 of 22 (permalink) Old 10-06-2010, 02:27 PM Thread Starter
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the metal prong actually pops right out of the black plug from the front. i've had it out already and was at pep boys with it to see if i could get a replacement.

the wire is coming out of the back of the black plug, the prong comes out from the front of the black plug when you disconnect the black plug from the main wiring harness plug.

the 4 grey plugs on the pc that go to the main injectors are fine, its just these little black plugs that go from the pc to the wiring harness are starting to get lose wires coming out of the back of the black plugs.

does anyone know where i could be able to get replacement prongs? and what size i need? dynojet customer service didn't know....

or am i just better off doing the direct wiring that tripage suggested?
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post #8 of 22 (permalink) Old 10-08-2010, 10:16 AM
 
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Pull the pin and measure it. Check here for a match.
http://www.easternbeaver.com/Main/El...onnectors.html




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post #9 of 22 (permalink) Old 10-08-2010, 12:23 PM Thread Starter
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post #10 of 22 (permalink) Old 10-08-2010, 12:28 PM
 
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Post a picture of the pin and I can help.




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post #11 of 22 (permalink) Old 10-08-2010, 01:42 PM Thread Starter
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post #12 of 22 (permalink) Old 10-08-2010, 04:40 PM Thread Starter
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post #13 of 22 (permalink) Old 10-08-2010, 05:05 PM
 
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Do the width of the plug.. Ones I have are 1/8 inch wide. Might be a little longer than the ones you have but should work..

These look like the ones you need.
http://www.easternbeaver.com/Main/El...onnectors.html




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post #14 of 22 (permalink) Old 10-08-2010, 05:19 PM
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damn it T you beat me to it, i got through the second post and had the same thought... good call

Never argue with stupid people. They will drag you down to their level, then beat you with experience
Don't argue with an idiot; people watching may not be able to tell the difference.
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post #15 of 22 (permalink) Old 10-10-2010, 04:31 PM Thread Starter
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so i did the direct wiring method today.

here is what i did:
1.) i removed about a half inch section of the plastic covering the wire that goes into the factory wiring harness plug. so i have about a half inch of wire with no cover on it directly behind the plug that the pc3 pin would connect to. (the exposed section is copper in color, so i'm assuming its copper wire?)
2.) i proceeded to make a gap (spread the wire in the middle, about 2-3cm gap) between the bundle of wires so i could put the wire from the pc3 through this gap.
3.) then i took the wire from the power commander (i also stripped some of the plastic covering off from this wire, so i had about half an inch of bare wire, which was silver in color), put it through the gap that i had made on the factory harness wire. then i wrapped the pc3 wire around the factory wire, so essentially i went through it and then around it.
4.) then i electrical taped everything to cover it up.

i started the bike, and after about a minute of idling it started to spit out a clear liquid from the exhaust. At first i thought it was just water, but there was a lot of it so i shut the bike off, and then i tried to smell the liquid by wiping some of it with my finger and sniffing it. it smelled a little like gas.

at this point i'm assuming its one of two things. either it is actually water and just smells a little like gas because its from the exhaust..
or
that it is gas, which is due to the wire that i tried to directly wire into the factory harness. is it possible that the injector now isn't working correctly and that is why i have gas coming out of the exhaust?

any suggestions, idea's, advice?

thanks everyone
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post #16 of 22 (permalink) Old 10-10-2010, 04:53 PM
 
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Twisting wires and electrical tape isn't hard wiring.. Get a solder gun and solder the wires, double check you have the correct wires before soldering. Cover with heat shrink. I am just guessing but your bike probably didn't have a good connection with the wire just shoved in before you cut them and now you have a good connection. Was most likely water in your exhaust that you were seeing and smelling small amounts of gas. If you got the map off power commander.com your map is probably running a little rich anyways.. Usually are from them so gas smell would be common from the exhaust. If you are confident the electrical tape is holding the wires good and tight then keep it but I don't trust tape. it goes back over time and will fall off causing a short or the wiring coming off and leaving you stranded. T




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post #17 of 22 (permalink) Old 10-10-2010, 06:55 PM
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Have you tried to contact Dynojet and ask if they can replace the plug?
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post #18 of 22 (permalink) Old 10-10-2010, 08:25 PM Thread Starter
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yea i did call them, and they were no help at all. they said they didn't have a replacement plug, or pin. and when i asked if they could tell me what size pin it was they said they would call me back with the info and they never did...
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post #19 of 22 (permalink) Old 10-10-2010, 10:00 PM
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post #20 of 22 (permalink) Old 10-11-2010, 12:16 AM Thread Starter
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i was looking at those too, i just dont know which ones to buy.

i sent a pm to dynojetreasearch here on the forum, hopefully he can help me out before i just buy both and see what works lol..
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post #21 of 22 (permalink) Old 10-11-2010, 01:06 AM
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It looks like the two connector part. Which of the top two, I don't know. Just order both, they are less than $2. You can order the pins in quatinties of 10 at the bottom as well.
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post #22 of 22 (permalink) Old 10-11-2010, 09:16 PM Thread Starter
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well the member that goes by the name "dynojetresearch" replied to my pm and is sending me some pins for free!!

he even offered to fix the harness free of charge if i shipped it to him.

very helpful guy, and great support from him.

looks like i should be good to go within the next week!!
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