Lucas headlamp wiring loom and it's connectors

Hi,
I just found out that my new Lucas headlamp loom has a mistake in one of it's headlamp connectors.
W and WR have been inverted (WR activates the starter relay and is connected to the RH handlebar push switch). I'm talking of the small 4 pole plastic connector that sits in the headlamp shell.
I would like to avoid cutting and inverting wires, so my question is: is there a way to remove the two connector pins so to invert them? I have tried but with no luck.
I'm working on a MK3.
Thanks, Ivo

Here is a photo: https://ln5.sync.com/dl/1fd217950/agfd3gs5-rp9pwamq-irztmvef-67tciggi

Never worked on these connectors but with others of similar type I have used a long sewing needle or jewelry/watch screwdriver inserted from the connector end to depress the tang on the connector that stops the wire being pulled out the back of the plastic block. Sometimes you need X ray eyes to find the tang. Once out rebend the tang if its too flat from being pressed by the needle and then insert the connector with wire in the correct slot, a small tug will confirm the tang has reached the right spot and re-engaged.

If there are 2 tangs then you need 2 needles and 3 hands.

Alternatively buy the kit and start from the beginning by cutting the fitted one off.

kommando said:

Never worked on these connectors but with others of similar type I have used a long sewing needle or jewelry/watch screwdriver inserted from the connector end to depress the tang on the connector that stops the wire being pulled out the back of the plastic block. Sometimes you need X ray eyes to find the tang. Once out rebend the tang if its too flat from being pressed by the needle and then insert the connector with wire in the correct slot, a small tug will confirm the tang has reached the right spot and re-engaged.

If there are 2 tangs then you need 2 needles and 3 hands.

Alternatively buy the kit and start from the beginning by cutting the fitted one off.

4 PIN CONNECTOR - Tricor Andy

www.tricor-andy.com

Click to expand...

Thanks, I placed an order for new connectors (but in the meantime I will give your solution a try)
Ivo

It looks like a Molex connector or copy. There is a tool to extract them by pushing in on the tangs. It is nothing more than a very thin tube with a plunger to push the pin out. All you need is a thin-walled tube and then wiggle and pull on the wire.
Russ

I have used the thin necked end of a Bic pen, but it can't beat the proper tool.

EDIT: Not a solution for this scenario - I used this for Molex connections with 360 degree access.

IIRC there is only one position where that pin will come out. You need to rotate the pin/wire in the plastic connector to the correct position and push on the two little "wings" on the pin with a thin tool. I think I used a ground down lock pick to make the tool. There are two or three small tabs in the plastic connector that prevents the use of a standard pin removal tool. It's a PITA until you get the first one done.

Thanks Deets55, I managed to remove one pin but I broke the second one!
Will have to replace the connector.
Ivo

The special tool always seems to cost more than a new connector with these type of connector.

Deets55 said:

IIRC there is only one position where that pin will come out. You need to rotate the pin/wire in the plastic connector to the correct position and push on the two little "wings" on the pin with a thin tool. I think I used a ground down lock pick to make the tool. There are two or three small tabs in the plastic connector that prevents the use of a standard pin removal tool. It's a PITA until you get the first one done.

Click to expand...

A little late now perhaps but a paperclip cut and bent as shown (2nd. pic.) to make a special tool will do the job...


With the pin tabs aligned as indicated...


...the tool is inserted into the plug (using pliers) as far as it will go ensuring each leg enters a gap where there's a tab...


...will release the pin.

Ivodispili said:

Thanks Deets55, I managed to remove one pin but I broke the second one!
Will have to replace the connector.
Ivo

Click to expand...

The connector, no, the pin yes.

I have made pin removal tools from thin walled brass tubing. The OD should be smaller than the cavity in the connector block, the ID larger than the pin body, but not by much. FYI, connector mfgrs offer pin removal tools from specialty supply houses.for their lines of products.

Slick