Ignition switch connector wiring opinions for worn wires going in to the connector

[Stratmanx]

1977 CB750F2

Had an issue with the bike cutting out and found that the wiring going into the ignition switch connector was stressed. If you moved it, power would cut out.

I've gotten a new connector and terminals and plan on cutting the wiring back about an inch and install the new terminals and then the new connector.

The issue is that there isn't much slack wire to work with.

Is it possible to take an xacto knife and slice back the main wiring harness outer wrap enough to obtain more of the wiring to the switch connector, or would it be the option to splice additional wiring onto the pre-existing wires ?

I do not want to replace the entire main wiring harness at this time.

Your thoughts ?

 

[brettp]

You might try cleaning any corrosion from the pins in the connector first. You might also have a pin work itself loose in the connector, try seating all of them (pull them with a pair of needle nose). I would do those things before cutting wire. If you do have to cut wire, maybe add some length to each wire before making a new connector.

 

[madmtnmotors]

Those wires don't look that bad. A common failure point is often the switch itself which will exhibit the same symptoms and will often respond in the same way when wiggling the connector at the switch. Test the switch before cutting up a potentially good harness.

 

[Loki]

The connectors in the multiplug are easily removed by pushing a small watchmakers screwdriver under the spade connector to release the locking tang then pull the spade connector out of the housing, this will allow close inspection and testing of the wiring and security of the crimp, etc. check the wires end to end with a multimeter on ohms and check for high resistance. Sometimes old wiring will fail under the insulation, give a tug on the connectors you might find one or more will pull out with some strands of copper attached, if so you've found the problem, if you're lucky you can trim back the end of the cable and be able to crimp on new connectors without losing too much cable.

Loki