Wiring Harness Fix - SOCALSPORTBIKES.ORG

Miruri · 07-31-2017, 11:30 PM

I wanted to get everyone's opinion on my "fix" for my busted wiring harness. Basically I was doing some tinkering with my CBR600RR in preparation for Button Willow. I was installing the tank which fell from where it was being held and broke the two connectors from the wiring harness that run the fuel pump and fuel level sensor.

So I bought new connectors, terminals, and tools, and I gave it my best effort until I realized I did not have a new connector that would fit one of the sockets. So I pushed the terminals back out of the connectors, crimped down the wiring with a pair of needle nose pliers and wrapped the base of each terminal with electrical tape.

The end result, instead of having two connectors that plug in I have four wires that plug into the sockets. The bike starts up fine, but I was curious do you think they will fall out when the bike is at high RPM's?

This is a temporary fix I plan on rebuilding the connectors and then soldering the connectors and new wires to the existing wiring harness, but hopefully this will work for a single day.

thtanner · 08-01-2017, 09:09 AM

If you can wiggle on it roughly for a minute or so and it doesn't pop out, I think it could skirt by for a day.

That being said can't you just solder the wires together right now and bypass the connector(s) entirely?

07-31-2017, 11:30 PM	#1
Miruri Rachel Join Date: Feb 2016 Location: Anaheim Feedback Rating: (0) Posts: 928 Experience: 5 years Trackdays: 10+ Bike(s): 2007 CBR600RR - Joker 2013 1199 Panigale - Dustin's Real Wife 2013 Aprilia RSV4 - Crash Bike	Wiring Harness Fix I wanted to get everyone's opinion on my "fix" for my busted wiring harness. Basically I was doing some tinkering with my CBR600RR in preparation for Button Willow. I was installing the tank which fell from where it was being held and broke the two connectors from the wiring harness that run the fuel pump and fuel level sensor. So I bought new connectors, terminals, and tools, and I gave it my best effort until I realized I did not have a new connector that would fit one of the sockets. So I pushed the terminals back out of the connectors, crimped down the wiring with a pair of needle nose pliers and wrapped the base of each terminal with electrical tape. The end result, instead of having two connectors that plug in I have four wires that plug into the sockets. The bike starts up fine, but I was curious do you think they will fall out when the bike is at high RPM's? This is a temporary fix I plan on rebuilding the connectors and then soldering the connectors and new wires to the existing wiring harness, but hopefully this will work for a single day.

08-01-2017, 09:09 AM	#2
thtanner VFR Rider Join Date: Oct 2016 Feedback Rating: (0) Posts: 216 Experience: 7 years Bike(s): 14 VFR800 FE 98 VFR800 FI 86 Vulcan 750	If you can wiggle on it roughly for a minute or so and it doesn't pop out, I think it could skirt by for a day. That being said can't you just solder the wires together right now and bypass the connector(s) entirely?