Melting wire, what is this

[WileyXB12X]

Like most Ulys, mine runs pretty hot and considerably hotter after some problems I had last summer. Anyway, I recently noticed a melted wire on the front of the engine, close to the bottom, near the oil filter, directly behind the joint between the header and the muffler. There's a bundle of wires and this little lone guy going into a sensor of some kind on the motor.

What is this and what kind of risk am I running if this melts through/breaks while riding?

Thanks - and I'll try to remember to get a pic tomorrow when it's still light out.

 

[WileyXB12X]

 

[08herobolt]

It looks like the bottom front of the bike in after the two into one and before the of the can. Is that correct?

 

[06buelly]

That is the wire to your voltage regulator (VR), some ppl call it a rectifier. mine went out last year. you'll know because your battery will need charged and/or all your electronics will shut off then bike will die when you're riding (happen to me literally 2 hours into a 5 hour adventure; left me stranded on interstate). It is a $170 fix if it ruins your VR. I would protect that wire asap to ensure you do not damage your VR or any of the charging system.

 

[WileyXB12X]

Yes, front of the bike, just behind the 2-1. The main bundle goes to the VR, but what's the little guy to the right of the main bundle that goes into the motor, where you can see the dribble of melted plastic?

Thanks for the heads up on the VR bundle though, I'll double check the wires in the sheeth and rewrap it.

 

[user_deleted]

wrong. the melted wire you depict in pic is the oil pressure switch wire. the voltage regulator plug is....looking at front of motor...over to the left and is a black rubber 90 degree plug with H-D bar and shield embossed on same. stronly recommend you properly repair that melted wire before riding it again.

 

[WileyXB12X]

wrong. the melted wire you depict in pic is the oil pressure switch wire. the voltage regulator plug is....looking at front of motor...over to the left and is a black rubber 90 degree plug with H-D bar and shield embossed on same. stronly recommend you properly repair that melted wire before riding it again.

Awesome, that's exactly what I needed to know. I knew the larger bundle with the melted sheath went to the regulator, it was the smaller one I didn't know - Oil Pressure Switch, got it.

Thanks so much!

 

[user_deleted]

my pleasure sir. i'd try and repair and bundle that wire with a protective heat shielding cover during repair.

 

[anrkizm95]

i'd try and repair and bundle that wire with a protective heat shielding cover during repair.

[up]

 

[WileyXB12X]

So the wire is not an individual piece but part of the whole wiring harness. So I've either got to splice in a new wire and spade (that's what Al at ASB suggested) or replace the whole freaking wiring harness.

Yes, I plan on putting an additional layer of heat shielding on both the individual wire and the bundle running to the VR. Any suggestion on what would work best sandwiched between the engine and the 2-to-1? That's a lot of heat right there.

I'll have to unplug it this weekend and see how it connects to the pressure switch. Is it just a fork or ring terminal under a nut? That would be pretty easy to splice in and crimp on.

 

[neddz]

hi,from memory only a fork and ring connector,10min fix..cheers

 

[WileyXB12X]

Turned out to be a female bullet connector pushed on to the screw coming out of the pressure sensor. The wire was still intact and the sheath around it too. So I went cheap and cut a piece of 3/8" tubing left over from the breather reroute and wrapped it around the whole bit. Seems to be holding fine.