wiring fault leading to list of odd issues

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dutch

Active member
Joined
May 8, 2012
Messages
32
So, it seems I have a bad ground and was wondering if someone here might be able to point me in the correct direction before I spend countless hours trouble shooting. The first symptom of what appears to be a wiring fault/bad ground/short is at times my fuel pump goes out and will not prime. It went out once and I jiggled the wires to the fuel pump at the butt of the frame and it started up. The second is at times my battery dies over night. the next day the starter will just click or be too weak to start the bike. The third is that when I pull in the clutch my battery power going to the starter seems to drop drastically(see video below), and at times when I pull in the clutch and release quickly sparks will fly from the clutch cable at the lever.
I've removed my fuel pump and took a look at the wires that sit inside the tank. They all seem to be fine with no short, although I have a new wire assembly kit on its way.

Thanks for your help.


http://youtu.be/i0J1vG99eGo
 
1-clutch cable acting as ground source which it is not designed to do. you have an obvious ground issue between engine and frame.
2-disconnect NEGATIVE battery cable. get test light and connect in series from cable end to NEGATIVE battery terminal. light goes on? you have a draw. if so get volt-meter and set to milliamps. again connect meter as you did the test light and read amp draw. post back with results.
 
Here is another video of me connecting one end of a jumper to the positive battery lead, then tapping my clutch lever with the other side.

Ummm..... yes that will make sparks. Why are you doing that?

The bike frame,engine and anything metal that is bolted to it SHOULD be grounded. Your battery is grounded to the tail subframe. That is bolted to the frame creating a mechanical ground. The frame is grounded to the engine with a heavy cable across the top engine mount. That cable is needed because the engine is installed with rubber mounts.

Let's say the top mount ground was bad, the engine is not properly grounded back to the battery. It will look for a ground and most likely take the path of your clutch cable (engine to bars). This could cause many problems with symptoms like yours.

I would check the heavy ground cable across your top engine mount. And stop welding on your clutch lever:)
 
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