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For the second time, my wife's cord has broken at the helmet connection (Honda 5 pin), both times during a long trips, (Blue Ridge Parkway and Cape Breton). Has anyone found a fix or alternative cord for this problem?

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The bounce in the cords causes that. The newer headsets come with a loop that holds that connection togather. On older headsets get a small black wire tie and strap the cord to the boom right at the helmet. That will solve your problem.
 
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