re-wiring tools and techniques

[dane_lindsay]

what is the best way to rewire to the 6-pin adapters(plugs); the clearance is tight, and how do i remove the pins,

[cernunos]

Sears/Craftsman makes a handy kit that includes about 100 connectors and a stripping/crimping tool for about 9 bucks. I prefer spade connectors when I'm wanting it to be removable and just double-twist and solder when I want it permanent. If you go the solder route get some heat shrink tubing to insulate the soldered connection. You can use electrical tape but the heat shrink is prettier and more durable. So if you get you a kit and some small spools of 16 and 18 guage wire and some heat shrink you'll be good to go. When I change out components where you want to re-use the existing plugs I just cut the wires about 2 inches from the connectors and splice in the new wiring. Or should I say, leave at least a couple inches when you cut so you have room to splice. Oh, and you can get a good soldering kit from Sears too for about 10-20 bucks. Love the GS and the forum.

C.......

[cummuterguy]

spend a couple extra dollars and use "weatherpack" connectors. you solder/crimp the wire to the terminal, then slide them into the connector.

a regular 'bullet' connector will get moisture in it, and eventually corrode, fail, wreak electrical havoc, etc.

Here's a single terminal weather pack connector (just the male end is shown), you can get them in several different configurations.

[Kerry]

If you decide to go the soldering and/or connector crimping route, see the mini-tutorial about 2/3 of the way down my Installing a "Digital 5 Function Voltmeter" on a Suzuki GS500 page.

[starwalt]

...and how do i remove the pins...

Almost every multi-pin connector has some form of latching mechanism to hold them in place. Please do fight the urge to yank the wire out. The strength of the latch is usually greater than the crimp on the wire.

I just looked at several of the connectors on my 90 and they all seem to have a different latch!
Glossary time!

Latch - the mechanical part that holds the connector in the housing.
Housing - the plastic part around several connectors.
Connector - the metal electrical part that is inserted in the housing.

Sometimes the latch is part of the housing and drops into a hole on the connector. Other times the latch is part of the connector and snaps over a ledge in the housing.

In most cases, a tool is required to release the latch and extract the connector from the housing. Sometimes the tools can be handmade or improvised from other items. Sometimes a vendor tool is required.

I will look into this more this week. If you could take a pic of the housing/connector in question, that would help greatly.