Posts
411
Joined
11/2/2020
Location
Walden, CO, USA
Edited Date/Time
5/6/2023 5:33pm
Anyone had one of the wires break and found an easy way to fix it without replacing the entire wire harness? The brown wire off the main harness broke, not really sure how but it did. Electrical repairs are not really something Im experienced with so looking for a little advice. From what I can find I dont see any OEM replacement connectors, just the entire harness.
**edit**
Think I've got a plan. Going to use marine heat shrink butt connectors.
It did on my ‘22 350. It’s pretty common. A heat shrink butt connector is the correct repair for this. A soldered joint makes a hard connection that will fail over time. The only better repair would be to run a new wire, but you need the correct terminals for the connectors and would have to cut the entire harness apart. I’m kinda surprised KTM used the wire they did and not a more flexible higher strand count wire.
Also for that size wire the correct butt connector is the green heat shrink one. They are harder to find, but they are for that small of wire. The next closest would be the salmon/red/pink connector.
Thanks for the heads up on the color/size! Went and picked some up and it was fixed in no time.
I just changed out the whole harness with this.
https://www.rockymountainatvmc.com/parts/tusk-engine-starter-switch-p
I suppose I will get around to fixing the OE harness some time.
This problem exist because the way the connector is mounted in the holder Pulling the connector out and zip tied to other wiring in a vertical position will keep the wires from breaking or simply hard wire it
The Shop
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
One of the First thing I do to my new KTM”s is sort out the wiring behind the number plate, zip ties & electrical tape the unused connectors & sometimes better routing. I think because the harness is also used for other models there are unnecessary connectors on the harness…. It’s better than it used to be but still needs to be cleaned up IMO….I had a wire break on my 22 350sfx last summer.
Had the same issue this weekend- google found this thread quickly and found I had a broken wire in the connector behind the from plate.
I ended up bypassing the connector and soldered in a new wire with some heat shrink. I am sure this will last longer than that connector..
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