Tips on how to disconnect and service electrical connections on motorcycle, auto and farm equipment

November 14, 2022

3 min read

Let’s review the process of disconnecting “most” electrical connectors. How about we use the procedure outlined in most service manuals:
1. Release lock tab
2. Firmly grab each not of connector housing and pull apart
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Yep that’s it, ask yourself this question:
Why then do technicians find it so hard to handle this task WITHOUT causing damage or hurting the integrity of the wiring?

My answer:
There are “assumed” steps missing from the procedure.
1. One simply step that is over looked when dealing with electrical connectors is cleaning them first. If debris is lodged behind the release or lock tab, there is no room for it to move out the way. Breakage is the next result you will see.
2. A technician does not actually know how the lock tab functions and just starts prying or bending.
My solution:
1. Read the service manual, looking for instruction that may give you a clue. Example: “push” or “pull” (I have yet to find one that says pry with pocket knife)
2. Always clean the connection BEFORE attempting anything (don’t be afraid to lube too)
3. Get good lighting so you can actually see what you’re working with
4. Get a magnifying glass or better yet take a picture on your smartphone and blow it up
5. If possible locate a new connector from the parts department and practice on.
6. Once you can SEE the locking tab, lightly ATTEMPT movement. Once confident follow the two steps from above to ACTUALLY disconnect the connector.
My thoughts are the same as always. You need a plan AHEAD of time to best use service manuals. Any longtime technician will tell you, planning, organization, and thinking before breaking are lessons learned over time.
My goal as you know is to shorten this time frame up dramatically. Join me in my EVERY MECHANIC SHOULD KNOW THIS SERIES. Any thoughts or ideas are welcomed.

Watch the video for removal, cleaning and connection procedures demonstrated on a connector commonly found on motorcycle, auto, truck and farm equipment.

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