Motorcycle Repair: electricial problem?, honda 750 shadow, liquid electrical tape


Question
2000 honda 750 shadow ace, Starter not working and low beam headlight not on, highbeam works. i have checked the head light and works if you push hard on the connector and stays on till you replace it on the housing and then goes out. you can repeat process with the same results. i have checked all fuses, connections, and battery. all ok except one connection. there is a blue plastic connector that runs two wires to the headlight connector. the two wires that run to the blue connector look melted and you can see the copper wire from one. two questions about this. 1. could this cause the starter switch not to work? 2. if i cut the blue plastic connector off and crimped the wires together would this be acceptable and fix my problem? also this has been an on going problem for the last three weeks. i replaced the battery and bent the metal pronges of the headlight out, and this corrected the problem for a week. ie starter worked and low beam work. now iam back where i started from, and yes i repeated this step and nothing, no light no starter switch. i have had this bike for 2.5 months. everything worked for this period. a lot of guys that work on there bikes said this might be a dead short. but i would like to see what you think.i hope this is understandable and not to confusing. i thank you for your time and advice.  

Answer
Hi Kevin,

Q: "...there is a blue plastic connector that runs two wires to the headlight connector. the two wires that run to the blue connector look melted and you can see the copper wire from one. two questions about this.

1. could this cause the starter switch not to work?

A:  Yes. I suspect your friends diagnosis is accurate.


2. if i cut the blue plastic connector off and crimped the wires together would this be acceptable and fix my problem?

A:  Yes. Make a clean repair by removing the damaged wiring and solderless connectors. Solder the wires directly together. Avoid over-heating the wires. Finish the task with liquid electrical tape and heat shrink tubing.

Respectfully,
Mark Shively