When I purchased my CoolSports 250, the previous owner mentioned that he had ridden it with the chain loose, when it through the chain and sliced through all of the wiring that comes out of the case. He spliced everything back (just stripped and twisted them back together) just enough to get it running, and left it. I am constantly having to check these connections when riding, and I would like to just replace the wires in their entirety. The question is, how hard is this to do? These arent the wires that come out of the area around the flywheel, but out of case itself. There are 6 wires all together.

I first thought I could make the splices more secure by adding some crimp connectors. Trying to get 6 crimp connectors on 6 small wires coming out of the case, when the group of wires coming out of the case are now only about 2 inches long.. well, it sux.

Given the design of these 250s (CoolSports, Kazuma, Roketa), with the group of wires so close to the front sprocket, I am sure this has happened before.

 

Unless you wanna take the casing apart and see if you replace the wires from where the originate. I'd suggest taking the electrical tape off where he twisted them together trying not to ruin them so they would have to be made any shorter. Keep them twisted but drop a few drops of hot solder on each connection. Cover each twisted connection as best you can with the solder to hold them together. Then If you dont wanna use electrical tape, maybe get some of that rubber coating stuff that they sell to coat tool handles and stuff. You could paint it around each connection to seal it really well. I still might wrap the whole group of wires up together with electrical tape and get some plastic ties and route it someway that they won't get hit and are out of the way.
Another way, if there is enough wire to work with, get some of those small male/female electrical wire connectors that you crimp on the wires. some of them come with little insulation sleeves to slide over the connection. Still, main thing, get them out of the way so they won't get hit.
Good luck, hope i gave u some ideas

 

Thanx for the reply Howmon. Some of your tips I had thought of, but I was trying to determine just how difficult it would be to replace the wires from the originating point. Where the wires go into the case, there is a small cover, with two screws holding it on. I cannot remove that small cover, without removing the cover to the flywheel. I was curious to know, if behind that small cover, is where the wires "plug in". If so, I could easily get a replacement bulk of wires from the dealer. However, if that small cover is simply there to hold the wires in place, and prevent them from being pulled out of the case, then it would be a waste of time to attempt to replace them entirely.

 

I would agree just solder them and get them out of the way!