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Bike:
2005 GSX-R750
Background of issues:
Previously I ran into issues with both my headlights (hi and lo beams) randomly turning off. I found this was related to the ignition button - this would either stick in the 'start' position rather than 'headlight on' position. Furthermore, the little black plate inside with the 4 metal nodes on it (which the button slides against for ignition and headlights) appears to be slightly malformed with one or two of the little metal nodes indented, causing the button to not make contact. I need to eventually switch this piece out.
Current issues:
After parking in a friend's driveway for 20 minutes I went to start my bike and the entire instrument cluster was dead. I checked all the fuses and easily-accessible wire harnesses but no success. Today I took apart the whole front end to install some new blinkers and decided to take a look at the main wire harness under the left-side intake. I found if I squeeze the harness together (squeeze very hard) the gauges turned back on!
I took the harness apart and found one of the wires is burnt out (?) (pictures attached). Has anyone had this happen before? I know next to nothing about the electricals - am I going to need to get a new harness or can I just trim the ends off the wire on each side of the harness and stick the wires back in? Also, I'm guessing this means there may be other issues - is it possible the failing start switch could have led to this?