Rubber terminal boot replacement for Yamaha XJ650 Maxim

prusaprinters

Replacement for the rubber wire terminal boots found on the solenoid-to-starter-motor cable and other places on my 1982 Yamaha Maxim XJ650 J and other similar motorcycles. These esoteric rubber parts tend to stiffen and crack before other parts wear out on these now ~40-year-old motorbikes. Why not print new ones with flexible filament?BackgroundThis design matches the part described on xj4ever.com as:HCP11431 Aftermarket solenoid-to-starter motor cable RUBBER TERMINAL BOOT, use 2 per cable. Fits over the end terminals and covers the solenoid terminal stud and the starter brush stud, protecting from moisture and shorts. Slightly smaller than original and will require some "persuasion" (and lubrication) to fit over the starter motor stud boss fitting properly. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, XJ900RK, and XJ1100 models.(source: https://xj4ever.com/catalog/d-7-starting.html)This design matches the dimensions of the original very closely.PrintingGeneral notesThe “avoid crossing perimeters” feature is advised to prevent stringing and oozing.Supports are needed for the print and are difficult but possible to remove in TPU. PrusaSlicer's “Snug” support setting made it easy to remove support from the overhang.ColorFabb varioShore TPUI printed this part in black ColorFabb varioShore TPU at 220°. With this filament, 20% density gyroid infill matched the stiffness of the original rubber part decently. The finished part is a bit stiffer than the OEM part, but with a bit of twisting and some silicone lubricant it went on fine.Other materialsIf you print this in another material and it works, let me know and I'll add instructions here!Included filesFusion files for easy remixingPrint files for TPU on Prusa MK3/S/+ with preset slicer settings for correct infill and avoiding stringingSTLUseI'll be happy to see anyone print this for their bike. Please post makes :)If you would like to buy or sell this part, please message me!