Mark in Northern Iowa
Well-Known Member
Club Contributor
I've already tossed out my replacement club pigtail, but I did do an up close inspection of it. (I have a de-pinning tool set). The actual crimped section of the wire and the crimp itself were perfect...like brand new. What actually failed were the copper strands were broken under the insulation at the point where it exits the body of the plug. That tells me that it's not actually the pigtail that was defective, but instead, the wires at the exit part of the pigtail plug hinge back and forth a little bit with each power stroke. After millions of little flex cycles, the copper conductors experienced metal fatigue and broke inside the insulation. I noticed this wiggling of the injector wires when I started my machine after my last repair, so I took up all the slack and zip-tied it to the surrounding wire bundle that was securely mounted to the engine with a strap. I'm convinced that if everyone did this to their injector wires, we wouldn't have any failures! Hope this helps guys.I sent you a message. I would like to get the old connector back to inspect it.
I will also send you replacements free once I find your old order.
Thanks.
Sent from my SM-G996U using Tapatalk
I'll take some pics of my repair next time I go to where I keep my rig. Gimme a day or soPictures Man, Pictures.
Show us pictures of the fix!!! haha 👍
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I have the injector wires on hand, but If I can fix it first, That would be better.
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Have a good day
Thanks for the feedback.I've already tossed out my replacement club pigtail, but I did do an up close inspection of it. (I have a de-pinning tool set). The actual crimped section of the wire and the crimp itself were perfect...like brand new. What actually failed were the copper strands were broken under the insulation at the point where it exits the body of the plug. That tells me that it's not actually the pigtail that was defective, but instead, the wires at the exit part of the pigtail plug hinge back and forth a little bit with each power stroke. After millions of little flex cycles, the copper conductors experienced metal fatigue and broke inside the insulation. I noticed this wiggling of the injector wires when I started my machine after my last repair, so I took up all the slack and zip-tied it to the surrounding wire bundle that was securely mounted to the engine with a strap. I'm convinced that if everyone did this to their injector wires, we wouldn't have any failures! Hope this helps guys.