Motorcycle Repair: Motorcycle Repair - Electrical, honda cm250, fuse box

Question
I have a 1982 Honda CM250 Custom. The bike experienced a total electrical failure.  I’ve isolated the problem to the 6 blade, nylon female connector (6 wire, one wire is the “hotâ€? from the battery/fuse box) which "plugs" the ignition switch into the wiring harness.  The female connector is on the battery side, the male connector is on the ignition switch side.  When the male and female connector is connected I read (via a multi-meter) no voltage on the male side of the connection.  When I disconnect the two, I have voltage on the female side.  Looking where the “hotâ€? wire goes into the female connector, I can see signs of corrosion on the female brass wire connector inside the nylon housing.  I’m assuming this could be my problem.  My question is this, how do I remove the brass connector to replace it without destroying the nylon connector?  Is there a special tool to remove the brass wire connectors and if so what is the tool called?  These appear to be the normal, common male/female brass, knife wire connectors so it should be easy to fix.

Answer
Hi Duane,

Yes, the corrosion is likely the cause of the problem.

Visit the following links to view two tools that separate electrical connectors. You may be able to fabricate a tool or use something suitable to do the task.

Use dielectric grease on all electrical connectors to help prevent corrosion and water shorting.


http://www.autobarn.net/liselconsep.html

http://buy1.snapon.com/catalog/item.asp?P65=&tool=&item_ID=11273&group_ID=1465&s...


Respectfully,
Mark Shively