Problem with new ignition switch

Posted by J on May 08, 2012; 6:58pm
URL: http://vintage-and-classic-hondas.81.s1.nabble.com/Problem-with-new-ignition-switch-tp3972238.html

So I'm about half-way done with my first restoration - a '71 Honda cb750 K1 - and I've run into a minor problem with my new ignition switch. In short, the male plug wont fit into the female end, despite the fact that they are both the same shape, size, orientation, made for the same year, and all of the internal prongs seem to line up with the corresponding receptors.

Both the ignition switch and the wiring harness it attaches to are new additions to the bike, I bought them both from relatively reputable sellers on Ebay and they were made new for this year and model so they should work.

All I've done so far is to widen the receptacles in the male plug in case the prongs in the female end are just too wide and cant fit into the narrow receptacles. I did this with a small pair of needse-nose pliars and some small nails, but there has been either no change or so little a change it is hard to even notice, and after a visual inspection, the receptacles seem wide enough for the prongs, yet still no luck.

Until I get this plug issue worked out, the bike is grounded and cannot start (can't bypass the switch either due to the round plug without splicing wires)

Any advice, tips, or stories of similar events are greatly appreciated.