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Discussion Starter #1
In the process of doing a major service on the 999R, which included a valve check and dialing in the cams. While putting the tank back on I had trouble with the one fuel connector and used a short section of wood to prop the seat up a couple of inches so I could see what was going on underneath the tank. As I walked to the workbench to get something, there was one of those expensive sounding crashes behind me as the tank fell off the bike and onto the floor.

Moment of silence, when there was a call from upstairs - my wife wanted to know who needs the ambulance, me or the bike...... Got to love her sense of humour.

No damage to the paint but the electrical connector to the fuel pump managed to rip itself out of on of the plastic plugs. Now I have four loose wires that refuse to go back in from where they originally came.

Any advice on how to put these wires back into the plastic socket again? They seem to press in until the rubber grommets are seated inside of the socket, but there is a guide plate on the inside that just makes things difficult to line up.

Cheers

SF
 

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If it’s like the on in these pictures (taken to explain how to remove to the pins to replace the nut with a metal one I happen to have for sale -- [shamless plug-ha], not install), it will probably help to remove the red insert. It could be that the tangs that catch the conductors are broken off so you’ll need to look to verify they are still there, otherwise there will be nothing to hold them in and you’ll need a new connector housing.

If all is OK, use a little Dielectric grease or just some WD-40 to help slide them in place. It may help to use a blunt probe to carefully push on the yellow seal to get them to seat.

Glad no other damage -- dent/paint….
 

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Discussion Starter #3
Bliksem!!!

Thank you for that feedback, not what I wanted to hear but it explains why the tangs do not want to stay put when I try to get them back in again.

Any idea where I can get a replacement connector housing from?

SF
 
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