Electrical Problems - Again

[Badbob]

I had my first ever breakdown on the road today. The GZ250 just stopped running. I managed to get over to the edge of the road with now problem. Here I am on the busiest stree in Tallahassee right at the beginning of the hour of scampering. I'm in the sun its 93 + degrees and threating to rain. Humidity must be at 90%. I got it started several times and it would just die within seconds. No power at all. The it would come back. This I noticed the running lights would flicker when I had power. Wiring. Last time the problem turned out to be a cut wire inside the headlight. Assuming this was where the problem was I proceeded to remove the headlight.

As I'm trying to get the headlight off the lights are going on and off. Moving the cable I had so carefully wrapped with Scotch electrical tape caused the power to go on and off. Not again. I not so carefully removed the tape so I can get to the wires. A sticky mess in the heat. By now seat is running into my eyes. I sure was happy to have a bandanna with me.

The wires all looked good but moving them around kept turning the power on an off. I've got to fix this. There is not going to be any get it in the right place and ride home. The GZ250 vibrates so much that it's not going to stay. After a few minutes and some choice words I found it. One of the pins in a connector was burned and it was arcing every time the wire was jiggled.

I had nothing to clean the pin with in my tool kit so I popped it out and cleaned it the best I could with my pocket knife. This didn't work so I took it back out and smashed the sides down as much as I dared with my pliers. This made it a bit difficult to get back together. I had to bend the male side to match exactly and worked. I jammed everything back in the headlight bucket and head for home via the shortlist route possible. Now its near the peak of the hour of scampering and were are barely moving. My 15-20 minute commute is now 45-60 minutes most of it siiting in the heat not moving. I made it home soaked with sweat but the bike is still working.

the pin in the connector is pretty much shot and the plastic is burned form the heat sot it needs to be replaced. I looked in the IPB for the GZ250 and apparently you can't buy the connector. Since I can't be the only person ever to have a problem like this does anyone have any suggestions what to use to replace the connector with. Hopefully I'l get some ideas before I start slicing and splicing.

The tape I wrapped everything with isn't working to well. I don't want to retape every few thousand miles. Does anyone know what the stuff is they wrap the wiring harnesses in? Its a lot more abrasion resistant the n electrical tape.