Use a Jackplug - Create work for comeone!

[sootie]

I am a recent contributor to this forum, but have been riding motorcycles for over 50 years, and my profession has centred very much around electronics and radio communications.

While considering construction and repair work around motorcycle electronics, a thought has struck me. More than 50% of all the equipment failures I see have something to do with 2.5 or 3.5mm jack plug interfacing. Actually the problems have been so numerous, that I now consider that this type of interfacing is unsatisfactory. Unfortunately, it is still widely used, with consumer grade electronics. It is also interesting to note that jack plug connectors are not used in automotive harnesses, or in professional military spec electronics. I hope this last observation helps to score the point.

These miniature jack plug connectors were originally just two wire, and were intended for light indoor consumer audio use. In this role they were reasonably satisfactory. They have now been extended to 3, 4 or even more connections, and the construction has been cheapened. Combine this with heavy handling, motorcycle dampness & vibration and you are probably looking at a failure sooner or later.

I can personally identify 6 different failure mechanisms within jack plug interfacing, but I won't bore you here. Suffice it to say that some of these are very difficult if not impossible to completely prevent.

There are several simple factors which can affect long term reliability of jack plug interfacing.
Here goes:
1. Mechanical support of the male jack plug in its fitted position will reduce problems.
2. If the female sleeve assembly is made of metal rather than plastic, the connection will survive better
3. The more connections involved, the less reliable the interface will be (a bit obvious!)
4. A few drops (no more!) of WD40 or similar around the assembly every few months improves matters
5. Really good setup wiring of the male & female assemblies helps
6. It is best not to leave DC voltage applied over long periods of non use

If readers are interested, I could go in to more detail, or permanent work arounds for these problems. Don't expect good solutions to be particularly easy though, just best practice for best reliability. In the meantime we can all do a lot better here with a little thought about the above. I have a couple of MP3 stereo jack plugs that have survived about 15,000kms on my bike without any problems so far. Unfortunately, I have also had a number of radio comms ones which didn't!

Sootie

[Akzle]

6.5mm or amphenol FTW!

[nathanwhite]

Just out of interest, if one were to build/acquire a system that had one lead taking stereo audio to the helmet and a mic line going back down, what then would be the most suitable connector?

[sootie]

Just out of interest, if one were to build/acquire a system that had one lead taking stereo audio to the helmet and a mic line going back down, what then would be the most suitable connector?

Baehr use a DIN connector on the helmet end. A good choice I think. I use a miniature DIN. These all work well, but good fitting is needed.
One of my riding mates uses a USB plug. That seems to work well too.
Nolan use a jackplug fitting at the helmet end. One of my mates had one, and it lasted about 500kms as predicted! (Cost heaps too!)
Most of the transceivers seem to connect to an external device (eg helmet) via a 2.5 or 3.5mm jack, and this is where trouble usually happens and is awkward to deal with. Some of the problem is at the fitted plug, and some is in the radio socket itself. The end result is the same - failure. Bikes provide a very harsh environment.

I have started hard wiring a tail into radios and using a DB9 (RS232) type connector on the end of it. So far, thousands of kms without a crackle on several bikes. It is not just comms electronics that gives trouble by the way.

Understanding that a problem is likely is probably the biggest step. I Hope this helps a bit. Sootie

[Gremlin]

Just out of interest, if one were to build/acquire a system that had one lead taking stereo audio to the helmet and a mic line going back down, what then would be the most suitable connector?

As said, Baehr uses DIN, it works. Waterproof and disconnects if uh... you're no longer in the same place

[nathanwhite]

Ah that's what it's called. Yes I've seen the connector on your bike Gremlin, just have only known it as a MIDI connector

[pete376403]

I use a 3 pin XLR (aka Cannon) socket as a external power point. Heavy duty, latching and big enough to take several amps (as well as a power outlet it also does double duty as the battery charger connection so I don't have to take off side panels and seat to get at the battery.)

It's what I plug the heated jacket into.

Probably a bit over the top as an audio connection.