Electrical Issues

[Slick]

I am having an electrical issue that involves the mini fuse box in the front fairing. At times the bike will not start unless I jiggled the wires under the "dash". I would move some wires around and hold their position while holding the start switch until the bike would start. Sometimes the bike would not turn-over unless I found that sweet spot.

So I narrowed it down to that little fuse box that has 3 fuses in it. When I twist that box, any and all starting issues go away. Well that was fine for a while because it did not happen very often. I did not want to pull the front fairing off to troubleshoot an issue that happened once, every once in a while. However, now it is all the time. Additionally, I would loose my dash/headlight/RPM gauge at times while riding, but the bike stayed running.

So, the last time I rode the bike I had to play with the fuse box to get her to start (kept turning over, but not starting) after a short ride and I noticed one fuse is getting really hot. The fuse getting BURNING hot is the one responsible for all the dash electronics including the starter. I only have a 10amp or 15amp in there, I wouldnt think that is it, so, I'm going to assume there is a ground somewhere in the system that is pulling excessive current, but where should I start? Anything other than the FSM, I checked that already.

P.S. Currently, my headlight is permanently out from the last time I rode.I dont think its the bulb, but I also havent had a chance to check.

[miked]

Hi Slick,

From what you have described mate, it sounds to me like the contacts in your fuse box are corroded or there is a build up of grime.
I would start by pulling the fuses and cleaning up the contacts (both on the fuses themselves and the holder they fit in to), while your there, check the wires going in to the back of it.
Unless everything in nice and clean and making good contact, you will get excessive heat build up from current draw.
Cheers

Mike

[RichBaker]

Could be a broken (inside the insulation) wire, too. Intermittent ground would be a distinct possibility.

[fj11.5]

did you find the problem mate 

[miked]

did you find the problem mate 

Yep, I'm in suspense too, did you manage to find the problem ?

Cheers

Mike

[Slick]

The notification system for replies just doesnt work for me, I lose/forget about post.
I had not had a chance to work on the bike for some time now, so this is where I'm at.

Update...

I continued to ride the bike even with the intermittent electrical issues (Not willing to put the work in for the little bit of time I had to ride). Eventually, I lost all power to the bike. During troubleshooting I found the connector for the ignition switch was a little melted as well as corroded, and this is where the system died. I was able to run a direct lead from the battery to the system (bypassing the ignition switch) to get the bike to run, but stopped there. I decided to get a new harness instead of chasing what seemed to be numerous wire shortage's.

Yesterday I started working on my baby again. I installed the new harness and checked to see if it would turn over, check! I still have the new carb boots to put on before I sync the carbs. Cant wait for her to be back on the road...

Side note:
I did find another melted connector when I took of the old harness located around the battery where the harness connects to the "Ignition Unit". It looks to be for a wire that runs under the carbs toward the front of the bike(Starter?Generator?). I believe it is 2 prong with 1 red wire.