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Cut Ignition Switch Wiring (Read 117 times)
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Cut Ignition Switch Wiring
01/20/21 at 23:32:20
 
Someone was cutting a few ignition switch wirings in our parking building.

I don't know much about soldering but would this be simple enough for me to learn and fix myself?
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justin_o_guy2
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Re: Cut Ignition Switch Wiring
Reply #1 - 01/21/21 at 01:42:41
 
If you've never soldered, I wouldn't recommend you start with that.

Pick up a hunk of wiring harness from a junk yard so you have different colors, sort out the sizes, a heavier jumper is okay, skinnier, not recommended.

Peel back tape, expose enough of a run to allow easy access, you will need wire cutters, strippers, butt connections and the pliers, well, they strip and cut, but the stripper part is kinda big and clunky. And they have flat spots for crimping butt connections on.

Get a few to waste.
Don't go crazy crushing the connections.
You can make the wire break in a few days.

If you pay attention to how you go about it you can stagger your splices so you don't wind up with a lump of butt connections to tape up.
Get some Made in America electrical tape.
You want to wrap,position your hands, unwrap a bit, pull tight, are
, walk it around, go back, wrapping again, til you like it.

It's not something most folks can wrap their head around, to cut more wire out instead of slamming connectors in, but I think you'll be ahead to cut wires out to different lengths so the repairs aren't all in one place.


You can get strippers for about twenty bucks like electricians use, put the wire in, lined up in the stripper to the right gauge wire, squeeze the handles and it grabs the wire and strips it.
You still need the ugly,cheap, not so good stripper available at harbor freight for crimping and cutting wires.

I'd want an Xacto for getting tape off.
I'm not there
Can't lay hands on it
If you just want to clean up the damage and put splices in, if you have room to do it, that would be quicker, just lumpy,
Buy some60\40 solder, resin, not acid core. Get a good soldering iron, tin the tip, tin some wires and solder them up.
You Tube surely has tutorials on soldering.
Connecting wires and running them in a line is easy.
Strip them
Lay the ends side by side
Like fingers pointing at each other
Then cross them in the middle
Wrap one wire one way
The other wire the other way
Solder that up

If you're completely prepared you slipped heat shrink tubing on the wire. Now slide it down the soldered joint and heat it. Tidy repair there
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Re: Cut Ignition Switch Wiring
Reply #2 - 01/21/21 at 05:07:18
 
I have a spare ignition switch with key if you want/need it.
Just pay shipping and it’s yours.
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Re: Cut Ignition Switch Wiring
Reply #3 - 01/21/21 at 06:15:23
 
Use solderless connectors for that. It will be repaired in just a few minutes.
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Re: Cut Ignition Switch Wiring
Reply #4 - 01/21/21 at 07:02:36
 
FIRST, DISCONNECT THE BATTERY before starting so you don't jump any wires across one another and pop a fuse.

Solderless crimp connectors would work fine, it would just add a little bulk to the harness in that area but nothing a few wraps with black electrical tape wouldn't cover up nicely.

If available, get the crimp connectors that are also heat shrink to ensure a water tight seal.  A small dab of dielectric grease on the connections before crimping isn't a bad idea either as this wards off rust on an exposed wire if your bike is subject to rain and moisture.

Nod butt connectors, but this is the idea...https://youtu.be/FTW5d1nTGo8
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Re: Cut Ignition Switch Wiring
Reply #5 - 01/21/21 at 07:40:16
 
Take LANCER up on his offer. It is an easy plug and play replacement.
If you do try repairing yours, don't do it on the bike. Remove the switch and connector, and work on a table. It will make soldering or crimping much easier.
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Re: Cut Ignition Switch Wiring
Reply #6 - 01/21/21 at 12:27:49
 
Thanks for the help everyone. I think I will look at getting another ignition switch and also try fix this one to learn.

Thanks for the offer LANCER but I am in NZ so imagine shipping could end up being pretty expensive from the US. If not I will definitely take you up on the offer.

Are the ignition switches from China you see on ebay alright?
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Re: Cut Ignition Switch Wiring
Reply #7 - 01/21/21 at 13:15:32
 
I'd do what got me on the road quickest.
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Re: Cut Ignition Switch Wiring
Reply #8 - 01/21/21 at 13:24:17
 
Bind wrote on 01/21/21 at 12:27:49:
Are the ignition switches from China you see on ebay alright?


I used one on my FZ6. Everything was correct but the harness length - it was too short. So I snipped the harness and used solderless connectors to reassemble a harness of the correct length.

But I'm sure that was just a fluke...

The down side of not reusing the original ignition switch is that you will have a separate key for the fuel cap as you do for the ignition. If that doesn't bother you, then get an ebay unit.
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Re: Cut Ignition Switch Wiring
Reply #9 - 01/21/21 at 15:46:33
 
It would be nice if you can work it on a table.  Get a cheap pencil soldering iron, some good low heat solder and some flux.  Watch a lot of youtubes and you can ride the next day.  This plus all they said up there.  
And quit messing with that guy's ole lady and he wont cut your wires anymore  Grin
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Re: Cut Ignition Switch Wiring
Reply #10 - 01/21/21 at 16:22:31
 
I know this doesn't help but the person who did it is a scumbag. And I hope he rots in hell if it exists.
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Re: Cut Ignition Switch Wiring
Reply #11 - 01/22/21 at 03:16:56
 
Do you have any "Fix It" or electronic repair places where you live?

If you remove the switch and connector you could drop it off to them and let them do the soldering repair for you.
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