GS1000 switch gear refurbishing help needed

[Agemax]

So i got another l/h handlebar switch assembly and want to strip it to clean it properly and redo the paint.
Problem i have is i cant get the wires out the bottom half of the casing. I have not seen one like this before. It seems the only way to do it is to remove all the pins from the molex connector.
Is there an easy way to remove these pins (the female side of the pins) or do i need a proper tool?
I have never seen a switch like this where removing the wiring is a major task!

 

[Rijko]

I have always used a very small screwdriver to bend the tabs in and back,
but there are several ways.

Nowadays i do use the proper tool but once you have done this the oldschool
way it's a piece of cake.

(Got an old Molex connector to practice on ?)

 

[Agemax]

none of the above methods seem to work, staples wont fit down the sides, neither will the smallest watch makers screwdrivers i have. I dont think its a proper Molex connector, but a OEM Suzuki connector plug.

 

[salty_monk]

They do have a tab on them & they do work like a molex. Clean it up, you'll be able to see it & figure it out. I did one with a small screwdriver on the 1100 just the other week.

 

[Agemax]

Tried everything now. Still cant get the pins out of the connector so i got 3 choices now;
Cut the wires, which i dont really want to do.
Cut a slot in the housing, which i dont really want to do.
Unsolder the wires from the switches, which seems the only option that doesn't involve cutting.....

 

[Rijko]

It is a bit of a pain to bend the tabs in and get the connectors out.

Do you have an old connector you could cut up and see how it works ?
You are looking for 2 hardly visible tabs in the middle, like in this picture.

Try to bend the tabs in, and do not pull the wire while doing that.
The tabs work like a barb and pulling the wire will make them resist bending in.

 

[Agemax]

It is a bit of a pain to bend the tabs in and get the connectors out.

Do you have an old connector you could cut up and see how it works ?
You are looking for 2 hardly visible tabs in the middle, like in this picture.

Try to bend the tabs in, and do not pull the wire while doing that.
The tabs work like a barb and pulling the wire will make them resist bending in.

View attachment 60076

I know how they work, and i know how they are supposed to come out, i just cant get anything down the sides of the pins to bend the tabs in, there is not enough room there for even the tiniest watchmakers screw driver i have.
Maybe i will raid my wifes sewing box and see if there is a small enough/strong enough needle that will work.
It is getting very frustrating now...........

 

[salty_monk]

Unless they are really brittle the plastic of the connector should "give" enough to get something down there. It definitely wasn't easy...

Personally I'd tape or clingfilm or foil them so they don't get sprayed & leave them in there. Might complicate the spray job & require more rotations but should be possible.

 

[Agemax]

I found a strong sewing needle that fits down the sides and is strong enough to bend the tabs in. Very fiddly but it does work. The block connector is full of old grease and crud which doesnt help. I have got 3 pins out but am leaving the plug soaking in degreaser for a while to help loosen it all up so i can see the pins better.

I have just modified/refurbished these 2 and want to do this one to the same standard.

 

[salty_monk]

Very nice.. Did you drop the white paint in off a pin?

 

[Agemax]

Very nice.. Did you drop the white paint in off a pin?

Thanks, i just filled in the recessed letters then wiped off the excess paint