JAE connectors and tools

[signcrafter]

Had a buddy that changed his handle bars on his harley and ran into some issues with pulling the wires threw and then they weren't long enough. Asked me if I could help him out so went and took a look. He pulled off a couple connectors when pulling it threw the bars. And also pulled the wires out of one connector. So got new connectors from Harley and need to get some pins and put the puzzle back together. Looking at the connectors they are JAE connectors. I'm looking to pick up a kit that comes with connectors and pins if they make one. Then a crimper if my astro one isn't right for these.

These are the type of connectors they are, https://www.digikey.com/en/products...JA75vKyWSlh5v-ziqCdiGoLy5SgcDNPxoCoC8QAvD_BwE

I'm having a hard time finding a kit with google. Do they make a kit that comes with pins and a selection of connectors like they have for weatherpack and deutch? I can buy them individually but for stuff like this I like to get a kit so I have what I need when I need it. I'm not a motorcycle guy and not sure when or if I will run into another issue but I like to buy stuff like this when I run into things so if I do need in the future I will have it. And then will my astro crimper, https://www.amazon.com/gp/product/B0045CUMLQ/?tag=atomicindus08-20 work or do I need to buy a different crimper for them?

 

[AdAstra]

The search term you want is the connector series: MX19 and/or MX1900. That brings up some loose pieces on eBay and Amazon. Else you're looking at piece parts on Digikey or Mouser, etc.

For a crimp tool for low volume contacts like these, I'd suggest the Hozan P-707 and understanding the attached.

 

[Uofime]

I wouldn’t seek out kits. Frequently they are made by no name brands from non certified parts. It is easy to make bad, out of spec connectors and hard to tell as an end user. At least until they leak or otherwise fail. ( I used to be a manufacturing engineer overseeing production of connectors and stampings).

Buy genuine parts from a trusted source. Digikey lists the terminals through the link above.

For the tool that Astro isn’t great. You need a standard “f” crimp for the core and since it doesn’t use individual cable seals you need a rounded over crimp for the insulation portion. You don’t want an f that pierces the insulation or that will cut the seal gland of the connector during insertion

 

[signcrafter]

Thanks for the info. So when I google F crimper it looks like what I call heart crimper that rolls the two small tabs over and crimps them? The hozen one suggested above calls it open barrel. To me it looks similar to Astros open barrel die?




Would this weather pack kit have the dies for the JAE pins?

https://www.amazon.com/dp/B01CN99TCA/?tag=atomicindus08-20

 

[AdAstra]

Open barrel just means it was stamped from sheet and will get folded over in the crimping process. (vs closed barrel where it’s already made round for you.)

The shape of the finished crimp can be a B (where the ends go down into the wire) or sometimes a rounded shape (usually only for the insulation part). The F name comes from looking at the terminals from the side, they can look like the letter F.

But these shapes are all general… matching the shape isn’t enough, each specific contact and wire combination has a different ideal height/width.

 

[AdAstra]

The weatherpack dies will be a dice roll.

Quoting myself from another thread:

I would recommend the Hozan P-707 for your application, because it is flexible and will enable you to do almost all contacts of this type in the future, with a little knowledge and care.

Crimpers for these small open barrel contacts that simultaneously do both the wire and insulation crimp will likely be less reliable unless you are dialed on exactly the right wire/insulation/contact pairing, which unlikely unless you are buying the specific manufacturer tool and using the wire they intend.

 

[signcrafter]

The weatherpack dies will be a dice roll.

Quoting myself from another thread:

I would recommend the Hozan P-707 for your application, because it is flexible and will enable you to do almost all contacts of this type in the future, with a little knowledge and care.

Crimpers for these small open barrel contacts that simultaneously do both the wire and insulation crimp will likely be less reliable unless you are dialed on exactly the right wire/insulation/contact pairing, which unlikely unless you are buying the specific manufacturer tool and using the wire they intend.

Going to order a 707 crimper. Thanks for the recommendation. Kind of interesting that there really isnt much info out there about JAE. Another member said harley switched from deutch to jae in 2012 so I would think there would be lots of info and part and tools would be easy to find.

 

[Uofime]

That hozon looks OK.
What size wire are you using?
Matching the wire size to the terminal size and the terminal size to the crimp die is what matters.
The Amazon ad shows some good looking crimps wile what you want.

Make sure you order a few extra terminals to figure out your process with the tool and wire.
When crimped correctly you should be able to pull the wire hard enough to break the wire while the crimp stays intact. This is easy with 18ga and smaller wire but bigger wire it’ll be all the force you can muster and the crimp stays intact.

I realize this is tough on a repair job as you may not have the same wire available for testing, in that case you just have to get or find something as similar as possible.

 

[signcrafter]

That hozon looks OK.
What size wire are you using?
Matching the wire size to the terminal size and the terminal size to the crimp die is what matters.
The Amazon ad shows some good looking crimps wile what you want.

Make sure you order a few extra terminals to figure out your process with the tool and wire.
When crimped correctly you should be able to pull the wire hard enough to break the wire while the crimp stays intact. This is easy with 18ga and smaller wire but bigger wire it’ll be all the force you can muster and the crimp stays intact.

I realize this is tough on a repair job as you may not have the same wire available for testing, in that case you just have to get or find something as similar as possible.

Is there a better crimper you can recommend? I've tried searching and it's pretty confusing because all sorts of open barrel crimpers are included in search results. And with my limited knowledge it's hard telling which ones may work.

Wire size was a few different from small to maybe 18 or 16 for the biggest. That is why I was kind of hoping to find a kit to have whatever I may need. But ordered a bunch of individual connectors and pins from digikey.

 

[Uofime]

Is there a better crimper you can recommend? I've tried searching and it's pretty confusing because all sorts of open barrel crimpers are included in search results. And with my limited knowledge it's hard telling which ones may work.

Wire size was a few different from small to maybe 18 or 16 for the biggest. That is why I was kind of hoping to find a kit to have whatever I may need. But ordered a bunch of individual connectors and pins from digikey.

I have not used that particular terminal series so I can’t say for sure. If you handed me them I’d try my ampseal or micropack 100 crimpers, but those cost a lot more than the hozans and I can’t say for sure they’d do the job well either without testing them.

You are right crimpers are complicated to pick even when you have experience.

I’d say Buy the hozans they are reasonably priced and look like they have crimp stations that should do the job. If they pass a pull test and don’t deform the terminals unnecessarily then you’re good to go. If they don’t then you’ll know what direction you need to go. Sorry I don’t have better advice