Just felt like throwing up a little post of the upgrade I’m doing to my 500 K0 wire harness and electrical panel. My Bike has those old circular pins, as opposed to blade style, connector housings and terminals. At the end of the season last year I was chasing a blown fuse issue that turned out to be in the handle bar control. Anyway, when I was disconnecting the plastic connector at the electrical panel to take some readings, clips started to break from the very old brittle connector housing. I don’t think that you can even get those circular hole type connectors anymore, so I just decided to buy some new blade type and tidy everything up. I didn’t want to clip the wires too short for re-crimping new connectors, so I simply cut all of the existing pins about halfway, crimped the new connectors on and soldered them to the partial pins. Nice solid connections. Of course the new connector housings do not fit in the old snap-in cut outs to lock them in, so I just installed rubber grommets inside the cut outs to protect the wiring and the new connectors will just be free hanging.
