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Old 11-28-2010, 02:16 AM   #151
Schlug
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Location: put something on and stay in that position.
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Quote:
Originally Posted by GS Addict
Damn,.....one more test............

You said:
I still have several hundred kOhms between (the now identified) X9430 and the yellow plug under the tank.

So:
Permanently connect the meter between these 2 points and get your reading.

Now start squeezing and manipulating the harness going from front to back and see of that reading suddenly changes. Likely it will point to the break.
GS Addict you're bloody genius.
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Old 11-28-2010, 12:18 PM   #152
roadrage
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Quote:
Originally Posted by Poolside

In general terms I understand what you mean. But I'm thinking Tage doesn't want the battery connected until he sorts out the issue on the large-gauge, unfused circuits. At least until he finds out what caused the open circuit.

The issue with your bike for instance, it was only a matter of time before an unfused short circuit happened. No sense courting disaster, especially when the tests can be performed with a meter instead of the battery.

Makes sense - I guess I've just been lucky in that regard.
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Old 11-29-2010, 04:41 AM   #153
Beemer Bob
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Why not run the temporary wire just to confirm you are on the right track.
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Old 11-29-2010, 06:28 AM   #154
tagesk OP
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Thumb



Let me present to you a worn 1.5mm wire, in which battery acid has been able to consume
all the copper.

[TaSK]
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Old 11-29-2010, 06:32 AM   #155
MattW
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Quote:
Originally Posted by tagesk


Let me present to you a worn 1.5mm wire, in which battery acid has been able to consume
all the copper.

[TaSK]
Result!

Excellent detective work TaSK!
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Old 11-29-2010, 06:35 AM   #156
John Smallberries
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Are you sure?

Are you sure it isn't just a low battery?

just kidding ... congratulations on digging to the root cause. Battery acid and insulation chafing/abrasion are a bad combination. I'll save this in my memory in case I need to diagnose a similar problem.

Thanks for the excellent photographs of every step. That is why these forums are so valuable!

I hope you are running again soon...
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Old 11-29-2010, 06:57 AM   #157
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Quote:
Originally Posted by tagesk
Let me present to you a worn 1.5mm wire, in which battery acid has been able to consume
all the copper.
Alright! That's must feel pretty good! Thanks for posting up the pics!

I'm curious. What did you need to remove to get to it? And what was the wire rubbing against?


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Old 11-29-2010, 07:31 AM   #158
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To ensure that the Main Wire Harness doesn't rub against the battery holder, which is mounted on rubber
"feet" and thus moves, the harness should be strapped to the airbox (if that is what it is called).
That strap must be firmly fastened. If not, the harness will have space to move, and will rub against
the loop where you attach the strap.

Probable cause: When the bike was assembled a decade ago, this strap wasn't pulled tight enough.
I didn't notice how tight it was when I cut it.

[TaSK]
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Old 11-29-2010, 07:36 AM   #159
tagesk OP
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Quote:
Originally Posted by Poolside
I'm curious. What did you need to remove to get to it?
The Main Harness is accessible in almost all it's length when the battery holder is removed.
To get that out you must remove the ABS (if present), and the "high-idle" cable from left handlebar.
The Monotronic must also be removed, but it can be moved aside without removing the contacts (so only two screws).

The main challenge now is to wrap tape around that harness with so little space. I'll probably won't manage to
wrap it in tape so I'll try to come up with some other solution.

[TaSK]
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Old 11-29-2010, 07:43 AM   #160
Mr. Magoo
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Would liquid electrical tape work? I frequently use it for repairs.

Congrats on the find!
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Old 11-29-2010, 08:06 AM   #161
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Bravo!!

That was a hell of a pile of detective work and I salute you and your patience. I will be sure to dig deep into my electrics during my winter maintenance. It will be next to impossible to prevent the problem you have experienced but now that we know the pitfalls who knows.

Good luck with the rewrapping of the harness.

Happy Motoring
drcool
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Old 11-29-2010, 08:26 AM   #162
Cogswell
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Quote:
Originally Posted by tagesk


Let me present to you a worn 1.5mm wire, in which battery acid has been able to consume
all the copper.

[TaSK]
I have been following along for the duration.

Glad you finally found your smoking gun.


Mike
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Old 11-29-2010, 09:09 AM   #163
GS Addict
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Quote:
Originally Posted by Mr. Magoo
Would liquid electrical tape work? I frequently use it for repairs.

Congrats on the find!
I this case; heavy wall heatshrink preferably with the butyl inside. Remember this wire is UNFUSED!!!!
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Old 11-29-2010, 09:13 AM   #164
GS Addict
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Quote:
Originally Posted by tagesk


Let me present to you a worn 1.5mm wire, in which battery acid has been able to consume
all the copper.

[TaSK]
Well done!!!
Just when one thinks they have seen just about everything.............
There is a similar trouble spot on the f650's, I repaired 3 now so far - sort of like a ticking time bomb - but in that case the harness fries because the B+ chafes to ground. 6 hours to repair the last one.
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Old 11-29-2010, 10:25 AM   #165
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Quote:
Originally Posted by GS Addict
There is a similar trouble spot on the f650's, I repaired 3 now so far - sort of like a ticking time bomb - but in that case the harness fries because the B+ chafes to ground. 6 hours to repair the last one.
Indeed, job well done by Tagesk.

@GS Addict, may I ask exactly where the spot is for the F650? (I would like to know as we have a F650 Funduro.......)
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