Broken wire fix??

ktm-5
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ktm-5
Edited Date/Time 12/4/2017 5:38pm


It's the wire that goes for the starter button but is part of the whole wire harness, is there a way to fix this or am I stuck buying a whole new harness? There has to be a way to fix it,any way to get connector put of plastic?




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ktm-5
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ktm-5 12/4/2017 11:50am
12/4/2017 11:50am
OK I got it out now to fix it

Micahdogg
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Micahdogg 12/4/2017 12:46pm
12/4/2017 12:46pm
I repaired a pin in a RM250 CDI wire harness from using an old Pioneer stereo wire harness. I just found a pin that was similar and did a little trimming to make it work. Its not rocket science if you have a few stereo wire harnesses laying around maybe you can find a workable match.

As a final resort, you can just use a male/female connector that runs outside that wire harness. Wrap it with some electrical tape and forget about it.

ktm-5
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ktm-5 12/4/2017 12:51pm
12/4/2017 12:51pm
I think I might try and solder the wire to this connector and if it doesn't work I will do like you said and just use two connectors to connect the wires. Crazy how easy it is to forget the simple things, that's y I love these sites, thank u
Tracktor
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Tracktor 12/4/2017 1:38pm
12/4/2017 1:38pm
You can buy new end connectors online if you can figure out size. Then it just slides & clips in the plastic piece.....

The Shop

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Rockinar
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Rockinar 12/4/2017 3:41pm
12/4/2017 3:41pm
You just need some new pins and connectors like this....


https://www.ebay.com/itm/3-Circuit-Connector-Set-of-3-Complete-molex-wi…



The metal part is called pin connectors.

https://www.ebay.com/itm/US-Stock-100pcs-Female-Pin-Dupont-Connector-Go…


I'd practice making a couple connectors before you take a stab on the connector on the bike.


beamer
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beamer 12/4/2017 5:38pm
12/4/2017 5:38pm
Most automotive shops have a large assortment of those types of things, i know we do. You might have good luck hitting one up. I’ve totally replaced harness connections on my quads a couple times, it’s not too difficult
stuartnewton
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stuartnewton 7/12/2025 5:31pm
7/12/2025 5:31pm
ktm-5 wrote:
OK I got it out now to fix it [img]https://p.vitalmx.com/photos/forums/2017/12/04/229407/s1200_1512416704571_1517943940.jpg[/img]
OK I got it out now to fix it

Hey mate how did you get it out?

FWYT
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FWYT 7/14/2025 10:06pm
7/14/2025 10:06pm
ktm-5 wrote:
OK I got it out now to fix it [img]https://p.vitalmx.com/photos/forums/2017/12/04/229407/s1200_1512416704571_1517943940.jpg[/img]
OK I got it out now to fix it

stuartnewton wrote:

Hey mate how did you get it out?

Not sure he'll see it as this is an old thread but I just did a bunch of those on my KTM 640. Those are Molex connectors. I'm guessing he managed to sorta rip it out. You need a special little pin disconnect tool that slips over the outside of the connector as it sits in the plug. This will push those barbs in and allow you to pull out the connector. It can be a pain. Sometimes the cheap pin removal tools work but I ended up getting a decent one that made the job much easier. The metal connectors you can get online or a good electrical shop will have them. To crimp them on, if you are real careful, you could do with some needle nose pliers of you can get a good, proper crimping tool.

This guy makes de-pinning seem easy. I found that it took a bit to get the hang of:
https://www.youtube.com/watch?v=H47vfMNxX_M

Another good one:
https://www.youtube.com/watch?v=kKkqXKfNuRQ

 

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