of mice and men

[mrlogix]

Well, I took it out for a couple of hours just to check everything out. Runs good. Stopped every so often and snugged the stator cover bolts up a little and checked the oil. Now it's like a seeping more than leaking. About a tablespoon an hour. Started it up the next morning (light rain) and went to take it back to the storage unit and get my truck. The bike would run until I turned the handlebars right, About 10 degrees past center and the bike would die. Checked all the wiring in the steering head area and the throttle cables. I isolated it down to two connectors located behind the front fairing going to the DDFI unit behind the bottom of the windscreen. Dried them out and it was fine. Will seal them later. Parked the bike in storage. Supposed to rain for the next few days. Will replace the stator cover gasket and change the o-ring on the filter cover and check the area where the wires come through the grommet for the stator. Felt good to ride again. Has been down since October.

 

[heagachongoose]

Glad things are coming along! Keep us posted [up]

 

[mrlogix]

pulled the stator cover and changed the gasket. While I was riding to warm it up to drain the oil, started to die intermittently. After some roadside diagnostics, whittled it down to the wiring harness in the steering head area. Left turn to center position all is good. Twist bars to the right from a degree or two from center and bike dies, battery dead shorts out, cluster reboots, no starter. Start bike, let idle and start tugging on different wire groups to try to identify which one is shorting out. Nothing, turn right dead. Finally got it to run long enough to get home and immediately take off all the plastic. Pulled the airbox outer and inner shells. Take off cluster bracket. No chaffed wires, no loose connections. Checked grounds, all good. Reassembled everything, no more problem so far. [confused] closed shop for the night. Ride more tomorrow after work. Think of anything I am missing?

 

[Cooter]

If it's repeatable by turning the forks, then it's got to be there somewhere. I've had terminals pull out of plugs and even broken wire with good insulation.

Turn the ignition on in the garage and wiggle small parts of the harness at a time, you'll find it.

 

[mrlogix]

Turn the ignition on in the garage and wiggle small parts of the harness at a time, you'll find it.

bike, let idle and start tugging on different wire groups to try to identify which one is shorting out. Nothing, turn right dead.

tried that before I stripped down the front end to physically check the harnesses and connectors. All good.

 

[mrlogix]

finally found it. The clue in the diagnostics was the instrument cluster losing power when it happened. Traced the power to the IC in the electrical manual and found that the power comes from the ignition switch. Removed the front fairing and headlight bracket so I could remove the igniton switch assy. It is held on by two (2) tamper-proof torx screws (T45). Dis-assembled the switch housing and found this.

soldered and heat shrinked the break

sorry for picture quality, stupid phone camera. Total time to repair-35 minutes

it's all good now. The harness to connector #33 (ignition switch connector) is a little tight on lock to lock turns of the forks. Cut the wire tie and gave it a little extra slack.

 

[sparky300]

[up]

 

[kronus]

Good find on the ignition, I was about to tell you to look there until I saw your pics. Same thing happened to my 08 1125R last year. Happened the same way first time i noticed was in the rain and then it got worse as the wire ripped apart.
You did do a better repair than I did! The wire severed closer to the board on mine and when I tried soldering it I ended up melting the contact out of the board [mad] . Had to pick up a different ignition.