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Valve Adjustment wire harness issue
- Thread starter sackman
- Start date
I broke one and decided I didnt want yo trust a zip tie. I bought a used harness but it was wrong so I cut off the old plug and wired in the new.
Yikes! Doing a 15k valve check/adjust in a couple weeks. Are the plug tabs super brittle? Mine is an 09 with some age on her frame.
just under 39K on mine..........
Had no issues with the locking tabs on my 2008 with 94K.
unfortunately the dealer that worked on mine at the 16K mark must have.....
This is why I am doing the valve check/adjust with an engineer friend. Maybe I am cynical, but I just do not trust dealer maintenance techs.
A lot of work I do comes from folks that have been mistreated from dealerships - it’s truly a shame actually…. We could probably start a thread here about ‘Dealership Performance Awards’ and vote monthly on the craziest thing seen.
Wayne, Carol & Blue
I was a auto/light truck dealer tech for over a decade. I treated everything like it was my own and took the time to do it right. I've seen a lot of hacks out there.
That being said with the help of the forum, SM and Wayne i took my time with my valves. I probably had 20 hrs in it. I think it took me almost 8 hrs just to get the valve cover off lol
I have worried about this when doing valve adjustments. Being gentle and careful goes without saying, however even then sometimes these tabs break.
My plan was to find a way to zip tie or otherwise secure the plug coils together so that they don't rattle apart after the bike is assembled (you will want to feel confident the plugs will not come undone).
The perfect, albeit expensive, solution, is to purchase that wire section of the harness. From Kawasaki it looks to be around $125. It is also possible to purchase it on ebay for less.
If you want to get the tool for removing the pins I can send you a plug. Or if you dont I can still send you a plug with enough wire to solder in to your harness.
I'd recommend replacing the connector. If it vibrates loose while you're riding, you'll loose that cylinder, and they are hard to get to. Here's a couple other sites that most likely have them.
www.corsa-technic.com
The place for all your motorcycle electric needs.
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Connector Kits, Terminals, Wiring, Tools | Corsa Technic
Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...
www.corsa-technic.com
Connector Kits, Terminals, Wiring, Tools | Corsa Technic
Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...
www.corsa-technic.com
Thanks, have one on order.I'd recommend replacing the connector. If it vibrates loose while you're riding, you'll loose that cylinder, and they are hard to get to. Here's a couple other sites that most likely have them.
The place for all your motorcycle electric needs.
We make and sell only the highest quality products.www.easternbeaver.com
Connector Kits, Terminals, Wiring, Tools | Corsa Technic
Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...
@Fred H. these are great resources!I'd recommend replacing the connector. If it vibrates loose while you're riding, you'll loose that cylinder, and they are hard to get to. Here's a couple other sites that most likely have them.
The place for all your motorcycle electric needs.
We make and sell only the highest quality products.www.easternbeaver.com
Connector Kits, Terminals, Wiring, Tools | Corsa Technic
Motorsport electrical products: OEM and hard to find terminals and connector kits, wiring, harness supplies, tooling, and sensors for modern and vintage motorcycle, automotive applications. Easy online shopping, low cost shipping options, to expedited around the world. We accept Paypal and...
Group - As luck would have it I’m turning around a valve check, blowing all the sand from the engine bay (shore stored machine) and out shoots a mouse nest and then I found my first mouse damaged wire that is too close to the connector to easily repair. See photos furthest below.
The connector is still good it’s just the wires are chewed and now oxidizing, breaking, etc.
Can these wires be released, cleaned up (as needed an extension put in to the wire run) and reset into the terminal? If so what is needed, new terminals connectors, any special tools for opening the connector, etc?
Thanks for the help from one’s who have been here before me…
Wayne, Carol & Blue
Looks like the map sensor wires. I'd release the pin, and simply solder and heat shrink the wires back together and then reinstall the pin. It looks like there is enough wire left to do a splice.
If there isn't enough wire, you may find once you get the pin extracted that you can solder tack a new wire directly into the existing pin. Otherwise you'll have to source a new pin and crimp and/or solder to the new pin.
If there isn't enough wire, you may find once you get the pin extracted that you can solder tack a new wire directly into the existing pin. Otherwise you'll have to source a new pin and crimp and/or solder to the new pin.
Thanks Fred I’ll probably try a solder splice first on the one wire with some heat shrink to weather proof.
If that’s a no go I’ll be learning how to release the pins on these connectors and redo, never bad to learn new tasks.
Bank to regularly scheduled program to get shims coming then I’ll deal with this.
Wayne, Carol & Blue
OP, how about some photos of what broke to help us better understand how to try to avoid this happening to us. I hate connectors cause they are all different and require different technique to get them apart. maybe some pics will let us see best way to remove this particular connector.
See below, this is what the OP was talking about. Note the locking clasp that broke off of the ignition coil sub harness female connector and sitting atop the cylinder 1 coil.
Wayne, Carol & Blue
I suspect you could secure that connector to the stick coil with a zip tie, but replacing the connector would definitely be a better and more permanent fix.
Oh, now I see from the photo it looks like a zip tie has already been put on it. As long as the zip tie can't slip off, that should work just fine.
Oh, now I see from the photo it looks like a zip tie has already been put on it. As long as the zip tie can't slip off, that should work just fine.
Fred the broken connector and zip tie photo was my photo not the original poster.
Further the one I showed was zip tied very temporarily and I replaced the harness connector as to your point (in a pinch it will work) it’s not a good long term solution. Could it work, yes!? The risk is if that zip tie or other holding mechanism let’s loose roadside it’s a tough go to get to it.
Wayne, Carol & Blue
Okay, it’s a bit DIY, but I think it will hold better than the clips that seem to break often.
I think it’s as aesthetic as this bunch of loose wires.
At the most, why not put an O-ring.
I think it’s as aesthetic as this bunch of loose wires.
At the most, why not put an O-ring.
Zip tie worked for me for a season or two. Next time in I wired in a new end .