Making "Heavy Duty" Electrical Connectors/Wire Ends/Terminals

Automotive
1

I am trying to help a friend whose motorcycle decided roasted ground cable sounded like a good appetizer to months of sitting and eventual change of ownership.
I know enough about trying to make new of these that most folks don’t bother and use universal type terminals. Being a bike, though, space is somewhat limited and I would REALLLY LIKE to see if I can’t reproduce the factory terminals/wires.
So, my questions:

  1. anybody know where to get battery terminals like this
  2. anyone know how to crimp/weld like the factory does, like this?
  3. anyone know where to source black/yellow wire, so I can use the factory color scheme? I’m rusty on gauging wire, but I’m thinking something around 10gauge…
  4. anyone know where to get the other plug pictured, for the smaller wire? I only know enough to know I can never find the right one…

I posted in Automotive, since this is for a motorcycle, but within the space, I wonder if the electrical and/or robotics folks might posses such knowledge/skills, too…

Thank you for reading. Please pass along if you think “so and so might know”. I appreciate any help I can get!

2

I would buy the factory replacements, but beyond that, I wouldn’t worry about color coding.

I would use some copper pipe and crimp it, bend it, then drill a hole in it for the large terminal.

I would use a normal blade terminal with plastic covers to do the other connection.

Paul

3

I do have the crimper for large terminals. Just ask. If it is a ground
wire, just pick up some black cable from autozone. (if they still carry it)

4

Thank you for your suggestions. Factory replacement, as in, year, make, model, does not appear to be an option, despite the bike being what I would consider “new enough”. (2002 Kawasaki). In truth, lengthxwire gauge should be good enough, but…

Welp. Off to “the zone” to check on their stock…

Thanks again!

5

Your best bet is probably to get an appropriately-sized ring lug and a length of appropriate gauge wire. (10 seems a bit narrow for a battery main) You can purchase the lugs at any auto parts store. If your wire needs exceed about 10 gauge, you may have to find a specialty store, or look into car audio suppliers. To get the bend, just bend the lug. They’re made of copper and are fairly malleable.

The plug is likely only available at a dealership for this model of motorcycle. If it can be salvaged, I would go that route. If it’s not salvageable, old motorcycle components usually have pretty good parts availability at the dealership. You won’t find anything for a bike at an auto parts store though. There’s not enough demand for bike parts, for the auto parts retail industry to spend time and money cataloging and stocking anything beyond batteries and the occasional oil filter.

6

The 10 gauge comment was referring to the smaller lead, which in the photos looks vaguely like a pringle…

Thank you for the suggestions…