Rewiring gen1 handlebars with a surprise.

Robert-A · 10-23-2014, 11:22 PM

I previously posted 4-8-2008:

Quote:

Originally Posted by Robert-A

My wiring continuity problem were all above the nut so a 6 wire sodering job and a XLR 6 pin connector (replaced on both CS and CSB) fixed the problem.

Even though she runs I want to return it to stock elcon connector before I 'put her out to pasture'. Like alot of us out there just waiting for that great deal on a CSB working or not and elcon CS wiring harness.

-Robert

Well "it's time to put her out to pasture". I bought a wiring harness and thought it was going to be easy. I didn't want to crack my handlebar and replace the wiring inside so I exposed two little white connectors on both the handlebars and the wiring harness. All colored wiring matched from handlebar to the new wiring harness with one small surprise: the new wiring harness had a 5 pin connector for the 5 wires but the connector coming out of the handlebar is a 6 pin connector for only 5 wires! (See photos)

Whoa. It should have been an easy plug and play. Now I am now looking for another wiring harness with elcon connectors to see if it has a 6 pin connector instead of the 5 pin connector before I do a intensive rewire and solder job.

Any guidance or wiring harnesses would be greatly appreciated,

Robert

JohnG · 10-25-2014, 08:10 AM

With 65 views and no responses, I think you finally found something that stumps the SC community!

Amimoto · 10-25-2014, 09:39 AM

The color code is the same, the six pin connector only have the 5 cable, just reconnect the cable according to the color code

Sent from my iPhone 6 using Tapatalk

Amimoto · 10-25-2014, 09:44 AM

Just rewire and solder the brown grey yellow blue orange accordingly and you'll be fine.

Sent from my iPhone 6 using Tapatalk

Robert-A · 10-25-2014, 12:30 PM

Quote:

Originally Posted by JohnG

With 65 views and no responses, I think you finally found something that stumps the SC community!

Thanks John, I was beginning to think I was being punished for being a lurker. ☺

Looks like a rewire is inevitable.

dale@thecoys.net · 10-25-2014, 01:39 PM

You could, of course, search the electronics parts houses (Newark, TE, Allied, maybe even Radio Shack) for the correct 6-contact connector, and buy that. It's very easy to move the contacts from the 5-contact connector to the 6-contact shell. Just push down the little piece of metal that's keeping it in the shell, pull it out, and put it in the new shell.

Robert-A · 10-25-2014, 05:41 PM

Quote:

Originally Posted by dale@thecoys.net

It's very easy to move the contacts from the 5-contact connector to the 6-contact shell. Just push down the little piece of metal that's keeping it in the shell, pull it out, and put it in the new shell.

You sir, are a genius!
No cutting, soldering, no problem!

Reassembly and tests to follow. Many thanks. I knew I could rely on the SC community.

A very relieved,
-Robert

dale@thecoys.net · 10-25-2014, 05:57 PM

Quote:

Originally Posted by Robert-A

You sir, are a genius!
No cutting, soldering, no problem!

Reassembly and tests to follow. Many thanks. I knew I could rely on the SC community.

A very relieved,
-Robert

Thanks. Glad to help.

Robert-A · 10-25-2014, 07:13 PM

Total unadulterated success!
Now that she is returned to OEM status I can finally put her out to pasture (Polo fields?).
Look for her in the stuff to buy and sell forum soon.

Thanks again for all the help of the SC community.

-Robert

JohnG · 10-26-2014, 08:06 AM

Awesome! That's great to hear. Congratulations!!

10-25-2014, 08:10 AM	#2
JohnG Uber Administrator Wise Segway Elder Join Date: Sep 2002 Location: Greater Boston Posts: 6,996	With 65 views and no responses, I think you finally found something that stumps the SC community! __________________ -- An original Segway employee, 2001-2005

10-25-2014, 09:44 AM	#4
Amimoto Member Join Date: Sep 2012 Location: Taiwan Posts: 195	Just rewire and solder the brown grey yellow blue orange accordingly and you'll be fine. Sent from my iPhone 6 using Tapatalk Last edited by Amimoto; 10-25-2014 at 01:35 PM..

10-25-2014, 01:39 PM	#6
dale@thecoys.net Senior Member Join Date: Dec 2005 Location: Lee's Summit, MO, USA Posts: 1,217	You could, of course, search the electronics parts houses (Newark, TE, Allied, maybe even Radio Shack) for the correct 6-contact connector, and buy that. It's very easy to move the contacts from the 5-contact connector to the 6-contact shell. Just push down the little piece of metal that's keeping it in the shell, pull it out, and put it in the new shell. Last edited by dale@thecoys.net; 10-25-2014 at 03:38 PM..

10-26-2014, 08:06 AM	#10
JohnG Uber Administrator Wise Segway Elder Join Date: Sep 2002 Location: Greater Boston Posts: 6,996	Awesome! That's great to hear. Congratulations!! __________________ -- An original Segway employee, 2001-2005

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10-25-2014, 09:39 AM	#3
Amimoto Member Join Date: Sep 2012 Location: Taiwan Posts: 195	The color code is the same, the six pin connector only have the 5 cable, just reconnect the cable according to the color code Sent from my iPhone 6 using Tapatalk

10-25-2014, 07:13 PM	#9
Robert-A Junior Member Join Date: Jul 2007 Location: Glendale CA. Posts: 82	Total unadulterated success! Now that she is returned to OEM status I can finally put her out to pasture (Polo fields?). Look for her in the stuff to buy and sell forum soon. Thanks again for all the help of the SC community. -Robert

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