well bike just broke down on the side of the road. actually some kind of electrical issue.
coasting to a stop light and pop, all electrical out and dead engine. Glad I was in town heading home.
OK home now and just rolled the bike off the Rollback.
On the side of the road All fuses tested good, nothing out in the fuse block under front right cover and the 30amp link and the starter fuse all good. 13.08 v at battery. Will dig into it later to see what I find.
Yes everything is original, no updates or Recalls done except the Blue Connector groud wire fix(by me).
Hate to hear that BR! I'm glad you weren't out on one of your favorite backroads in the middle of nowhere. Hope you get her fixed quick with little pain.
[image: View Post]Chuckster, on 09 June 2012 - 02:49 PM, said:
Hate to hear that BR! I'm glad you weren't out on one of your favorite backroads in the middle of nowhere. Hope you get her fixed quick with little pain.
Chuck
Thanks, REALLY glad it didn't happen during the Tmac!!!!!!!!!!!!!!! :huh:
Sorry to hear about that, BR, but at least you know what it is. Also, glad you were close to home. My breakdown last Fall happened 6 hours from home. :sad:
I pulled off both side panels and checked the RR connections(good), the start switch plug and all the fuses again, then looked at the blue connector for melting & such, but nothing! Turned on the key and presto had lights and bike started right up. I hate that! :ohmy:
That's when I decided to pop open the blue connector, but it wouldn't seperate! Pried it apart and found the one burnt wire. Not sure what it's to yet, will check the diagram soon.
BR
BTW what is that web site where you can check recall status on our bikes?
If the connection thingy's(blades) are tightened/squeezed they are less likely to have a problem.......... if they were hard wired then it's going to be a pain in the future if needed to unplug.
I went though a lot of my plugs and unhooked them so I could squeeze them to a tighter locked connection, but you have to pull each wire insert out of the plug box, which takes a very thin slim-jim type tool.
Never wanted any Dealer to touch my bike, but I think i'll save all the work and let them replace the entire harness as Both sides of the blue connector are damaged.
Local Dealer says the 26th is the first day they can get it in and it could be a week before they even look at it after that! :huh:
Donna's Gixxer 600 and my neighbors Blackbird had similar connector failures and I just rewired the failed wires with heavy duty male/female connectors. Cleaned up the blue connector so it went together smoothly and no problems after. I fixed my neighbor's BB 8 years ago and it is still fine. We traded the gixxer about 5 months after its last fix. FWIW the gixxer had about 4 different connector failures over 2 years that I fixed the same way. Talk about thin gauge wire and lite duty connectors the Suzuki GSXR series is exponentially more delicate than a Honda.
Fix the one bad wire and clamp it back together and blow that thing up right! That rattle may have been an arc maybe?
I think we should hold a raffle on the rattle. I say it's a tip of a feeler gauge that broke off while your were sleeping and HS was checking your valves.;)
Yeah, I'm sure I could bypass the connector on that one bad wire and be good for some time, but if honda is willing to pay for parts and labor for me to have a new harness I'm good with that.
Kevin, try to get your old harness(es) back from the dealer. I told my guys that I wanted mine back, they said the had to hang onto it in case Honda wanted it back. Couple months later I asked again and one of the techs took it down off a shelf and sent me home with it. It's real nice to have the spare wire and connectors for other projects.
Also, some folks had problems after the recall swap, in some cases the techs didn't route the new front sub harness correctly, allowing it to rub and short out on the subframe. Don't overlook it - my bike was done by a guy I know real well, been a tech longer than I've been alive and he missed it. I found it because I knew about it and took my bike apart to check all their work.
I also took off all the big stuff to make it easier for them, minimize risk of paint damage, and to make it easier for to check their work.
Also BR, the black/red wire is just headlight circuits +12v power feed. A burned up connector here would not affect the bike running.
Can you tell me if your 30 amp fuse holder was ever cut out and replaced with something aftermarket? This circuit is notorious for causing the sudden power cut due to heat buildup.
Curious if you remember whether the clock was working or not? The clock will work even if the main 30 amp fuse circuit is interrupted, but there will be no other power evident.
BR it sounds like your ticking time bomb ie wiring recall finally went bang. Maybe I need to get my 03 in for the recall too. I'd like to wait until premium riding season is over but that will be around December or January for me. If the dealer is busy now I don't know how much of a priority they would put on my 06 recall notice. I can hear the service manager say "So you've had 6 years to bring your bike in and now you want it back ASAP! My response would be "Yep!" :tour:
[image: View Post]kaldek, on 10 June 2012 - 05:18 AM, said:
Also BR, the black/red wire is just headlight circuits +12v power feed. A burned up connector here would not affect the bike running.
Can you tell me if your 30 amp fuse holder was ever cut out and replaced with something aftermarket? This circuit is notorious for causing the sudden power cut due to heat buildup.
Curious if you remember whether the clock was working or not? The clock will work even if the main 30 amp fuse circuit is interrupted, but there will be no other power evident.
Thanks for the info as I hadn't looked into what that Blk/red wire was too yet. Yes I redid the 30amp fuse holder at least 6 years ago with a10gauge unit and it still looks good. I did the Blue connector ground fix 3-4 years ago, didn't know there were issues with any other circut other than the ground loop.
I plan to call a few other area Dealers to see if they can get it in sooner.
Guess I could always through my plates on my Track Vtec in teh mean time! :tour:
BTW I can't really bitch about the problem, I've run the piss out of this bike for almost 100k miles on all original equipment w/o issue. Also ignored All Recalls as I don't trust Dealer work whatsoever. Really glad & lucky it happened around town and not dyas out during a major trip like the Tmac which would have a real bummer!
[image: View Post]Baileyrock, on 09 June 2012 - 08:31 PM, said:
Local Dealer says the 26th is the first day they can get it in and it could be a week before they even look at it after that! :huh:
BR
Honda most likely has a set price they pay for this fix and it's most likely a lot less than what their shop rate is. So best guess its a low priority for them and they'll look at it whenever their is downtime.
Good luck! Dealer has had mine for 3 weeks now. Yikes.But, just PMed another member about another bike , gotta have 2 (used) bikes since I live a long way from any service.
It is the standard operating procedure at many Honda workshops over here when total electrical failure takes place...
This yellow connector on the 6th gen (orange on the 5th gen) is a POS... Insert Nike add here.
I did it some 20,000 km ago after having burnt out 2 stators... recently pulled my bike completely apart to graft the chasis onto a 2007 model (call it a face lift if you like)... the stator was looking quite good... and I haven't blown any fuses, no connectors have burnt out, no electrical glitches not even blown a bulb or fuse since then...
It is the standard operating procedure at many Honda workshops over here when total electrical failure takes place...
This yellow connector on the 6th gen (orange on the 5th gen) is a POS... Insert Nike add here.
I did it some 20,000 km ago after having burnt out 2 stators... recently pulled my bike completely apart to graft the chasis onto a 2007 model (call it a face lift if you like)... the stator was looking quite good... and I haven't blown any fuses, no connectors have burnt out, no electrical glitches not even blown a bulb or fuse since then...
Thanks!
Do you suggest doing this to a brand new harness?
It is the standard operating procedure at many Honda workshops over here when total electrical failure takes place...
This yellow connector on the 6th gen (orange on the 5th gen) is a POS... Insert Nike add here.
I did it some 20,000 km ago after having burnt out 2 stators... recently pulled my bike completely apart to graft the chasis onto a 2007 model (call it a face lift if you like)... the stator was looking quite good... and I haven't blown any fuses, no connectors have burnt out, no electrical glitches not even blown a bulb or fuse since then...
Thanks!
Do you suggest doing this to a brand new harness?
BR
In a word: Yes....
Unless they've replaced that substandard connector with a completely different and much more effective one in the new front subharness, yes i would.
But be sure to have it soldered properly... a regular soldering iron will NOT DO THE JOB with such a mass of cables... have it professionally done... Dremmel makes a blowtorch soldering iron, it's what we used to get this done right... the cables have to heat up and absorb the solder, you can see how it soaks in... otherwise you're just painting the outside of the mass of cables with the solder and creating "cold joints" or completely non-existant ones and back where you started.
The readouts on my voltmeter since are rocksolid stable.
Otherwise you can simply rewire each wire to wire connection with decent individual connectors... (much more fiddley job but probably more reliable even still).
Just spoke with the Dealer and he was sending pics of the harness damage to Honda as we were speaking! He said it shouldn't be an issue, they just wanted pics before saying "Fix It" hopefully! :smile:
[image: View Post]Baileyrock, on 14 June 2012 - 05:57 PM, said:
Still nothing from the Dealer, but do have a shot of my ride home! :rolleyes:
[image: Attachment] 2012-06-09 14.23.56.jpg
Standing there in your skivies in front of your bike, I soooo want to say something witty about the size of your "luggage" BR ... but it's not fair when a bloke's bike is broken down ...!
[image: View Post]TexOz, on 15 June 2012 - 05:30 PM, said:
[image: View Post]Baileyrock, on 14 June 2012 - 05:57 PM, said:
Still nothing from the Dealer, but do have a shot of my ride home! :rolleyes:
[image: Attachment] 2012-06-09 14.23.56.jpg
Standing there in your skivies in front of your bike, I soooo want to say something witty about the size of your "luggage" BR ... but it's not fair when a bloke's bike is broken down ...!
[image: View Post]Baileyrock, on 14 June 2012 - 05:57 PM, said:
Still nothing from the Dealer, but do have a shot of my ride home! :rolleyes:
[image: Attachment] 2012-06-09 14.23.56.jpg
So let me get this straight, the tow truck guy got you out of your pants AND took your picture?!? :huh:
That sounds bad, even for Tennessee!
:tongue: :laugh:
Should be fixed soon Kev, my dealer did the same thing - sent pics and then got the harness in. They did both no problem, had it about a week if I remember right.
Well the good news is that Honda is replacing everything and the harnesses are being shipped soon! :smile:
They said they were going to push to have it done by Sat.
Bad news is that I need a bike by Friday to ride down to the AMA Superbike races at Barber. :sad:
Still working on getting a back-up bike going by Friday! :ph34r:
I soooo wanted to make smart comments about some old guy with bad lags standing in front of a truck because his bike wouldn't run. Because other people have seen fit to do this and I'm older, I chose to say: that's too bad. I hope they get it repaired in short order. :smile: :smile: :smile:
Some days I swear I wish I was in the USA. Then I could actually be of more use to most of you, as I've traced practically every wire in that damned wiring harness, and I know where to poke and prod to find the source of problems. Few dealers have the time to fix this stuff, or the knowledge on where to look, so they just throw parts at it.
It could be rather embarrassing when they replace the entire harness and find out it's something simple like the ignition barrel.
[image: View Post]kaldek, on 19 June 2012 - 06:37 PM, said:
Some days I swear I wish I was in the USA. Then I could actually be of more use to most of you, as I've traced practically every wire in that damned wiring harness, and I know where to poke and prod to find the source of problems. Few dealers have the time to fix this stuff, or the knowledge on where to look, so they just throw parts at it.
It could be rather embarrassing when they replace the entire harness and find out it's something simple like the ignition barrel.
If your ever in Nashville you have place to stay! :smile:
And you don't even have to work on my bike! :tongue:
![[image: Posted Image]](http://www.ahm-ownerlink.com/images/global/glo_space.gif){kind=link}
![[image: Posted Image]](http://www.ahm-ownerlink.com/images/global/glo_dashline.gif){kind=link}