XJ650 - Stubborn one-pin connectors

Been trying to install some rubber grommets in my headlight bucket, and I need to disconnect everything in there to do that. However, I am having such trouble getting these little guys disconnected:



I tried cutting the insulation so that I could get a tool in there to loosen it, but I have had no luck. I think it’s crimped together, so even though I can get it to wiggle a bit, it is stuck fast beyond a certain point.

Anyone have tips for these? Or am I going to have to cut these wires and install a new connector?

 

Don't cut the wires if you can avoid it. You could try a small screwdriver blade under the plastic to see if you can push it off.

 

I am stunned at how clean and new everything looks in there. How many miles on that bike? In my experience it takes about 2 laps around the block to start gathering dirt and dust on pretty much everything even in the headlight bucket.

 

It came to me with 3900 miles on it when I got it last July. There’s now 7900 on the clock, so I have more than doubled the original amount myself.

The wires have always been clean, but I make pretty routine use of electrical contact cleaner in there too, whenever I take the connectors apart. Rust has started to creep into the bucket itself… considering taking some sandpaper and WD40 in there to try to get rid of it. I know some level of rust is inevitable, but I don’t want it to compromise the metal.

For the connector, I guess I’ll try the screwdriver suggestion. I’ve tried gently prying at the female connector, but it does not want to budge.

 

Yes that is super-clean looking. That's the bullet style terminals, they are tight-tight-tight, you may have to grasp one end with a pair of pliers and pull/yank on the other end to get them to separate, just a very tight friction-fit.

 

I put the needle nose pliers inside the sleeving to grasp that end with one hand, and then the outer part with my other hand so your not pulling on the wire and stretching the insulation or possibly weakening some of the wire strands. A shot of WD-40 or other lubricant inside the sleeving might help.