Problem: swollen sealing ring in the control switch connector

The control switch on my MX 1.0 has been misbehaving - the status LED is always dimly light and the bike occasionally behaves as if the buttons are held down.

Sounds like dirt in the switch, yes? But taking that apart and cleaning it thoroughly didn't help.

So next steps is the connector, where a found this issue. The sealing ring is swollen and buldges out. It isn't sealing or keeping dirt out. I think contamination here is causing leakage between the wires leading to my control switch problems, or the sealing ring is pressing on the pins. Current is tracking through dirt on the ring and making weak shorts between the pins. But the seal won't even sit back into the right place so the connector can be connected.

Anyone else had this issue? Is there a resolution other than just running without the sealing ring?

(And yes, I have raised a support ticket with Stark on this but no response yet.)

happyinmotion said:

I think contamination here is causing leakage between the wires leading to my control switch problems

Click to expand...

Unless you cleaned the connector before taking the pictures, I doubt that the little dirt I see has caused problems. Maybe water.
One thing to consider is that this connector, unlike the other two, has the female socket below the male plug and therefore anything small that is pushed down by gravity has more chances to pass through their seam.

happyinmotion said:

or the sealing ring is pressing on the pins.

Click to expand...

I doubt that it can happen, given the shape of the white plastic plug and socket.

happyinmotion said:

Is there a resolution other than just running without the sealing ring?

Click to expand...

Maybe trying to cut it, shorten it and use it with a small gap.

Anyways, I have seen that kind of connector in my old Italian Husqvarna 610, too: it must be fairly common. Gemini, to whom I've shown your picture, says it belongs to the JWPF line of connectors.
Now, I don't know the size of the seal ring you need, but these guys, for example, may have a replacement:
Sale JST JWPF Series 8 Hole Seal Ring 08R-JWPF-VSLE-D

Further checking confirms to me that the sealing ring is definitely the cause of the issue. Joining the plug and socket without the sealing ring causes the control switch to work as expected. Joining the plug and socket with the ring in place causes phantom signals. It is also much harder to close up the connector, implying the seal ring is squished by the face of the male plug. That would cause to press on the pins.

Thanks for identifying the connector. I can use that to order a replacement sealing ring...

... no wait, I'm in NZ so I'm going to have to get a whole new connector from overseas to just get the seal. No suppliers that I can find keep them in stock in country so I guess I'll wait two weeks for the parts to turn up. Then we'll know if this fixes the problem.

The seals seem to be generally only available with the housing. That site offering them without housing seems to be a seal only manufacturer.
Good news is the housing is less than €2 incl. VAT
Here's how to put the terminals in and out (from 5:15) You won't need that tool when you find something that you can make work

If you are still in warranty, Stark should help.
If not:
I believe this link is the right connectors, you could buy a couple just to get the seals.
There are variations with 2,3,4,6, or 8 pins.