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Old 11-11-2010, 12:48 PM   #12
Billy_Goat's Avatar
Joined: Aug 2010
Location: Los Angeles
Oddometer: 118
I'd like to share a bizarre problem I had with my 2003 DR650SE.

When I turned the bars all the way to the left the engine would die. It would crank over but not start, lights and everything else worked too.

After confirming that it wasn't the choke or throttle cables, I began checking all the electrical connectors. All the connectors seemed fine so I started messing with the harness and found that when I wiggled the harness the engine would die regardless of what position the bars were in. I checked all the connectors over and over to no avail, so I unwrapped the harness from the speedo to the air box. I found NO damaged wires at all, none. I would start the bike and if I wiggled the wires it would die, very frustrating to say the least. I then separated all the non-essential wires, i.e. lights, horn, etc from the critical wires. I was at my wits end and about to set the bike on fire when it dawned on me that I should check the wires for continuity. So I used the sharp probe tips of my ammeter to check the resistance in the wires and found one wire that would lose continuity if shaken. It was orange w/black stripe, critical for the ignition. The wire had no visible damage at all. I soldered in a replacement and haven't had a problem since.

Cliff notes:
Had intermittent electrical problem causing bike to die.
Toned out wires inside harness and found a bad wire. Orange w/blk
Soldered in replacement.

Check the tension of the harness when bars are at full left.
If it's too tight, free it up a little.
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