OzSTOC
General Category => General Discussion => Topic started by: winston66 on March 23, 2016, 06:25:34 PM
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This is one for the Gurus.
My 2003 ST1300
Problem,
When turning off the ign. The motor shuts down as normal. However the lights stay on as well as all of he instrument lights .
The indicators behave and do not operate with the ign. turned off.
The only way that I can turn off the head lights and dash is to thumb the start button with the ign. in the off position. Everything then shuts down.
A current leakage test of the battery will show a momentary current of approx 29 milliamps for a very short time, about a half second , it then reduces to a very low amount of point 7 of a milliamp.
I would think that this would be normal.
I have exhaustively checked all of the wiring and connectors that I can access, there is no sign of degradation, ie. dirty or bad connectors , worn or abraded wires, etc,etc.
There are no fault codes from the F1 light.
All of the relays , fuses etc, appear to be in good condition and everything seems to be clean neat and dry.
I have not added any farkles etc. to the bike and everything seems to be stock standard, except for the electronic MC cruise that the PO had fitted.
The bike runs and operates flawlessly, except for this glitch with the operation of the headlights.
Needless to say I am stumped by this one.
I welcome any suggestions and or comments.
Cheers to all,
Winston66
Northampton, Western Australia
Lets see what you all can offer
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The only thing I can think of is possibly a sticky headlight relay. The contacts may have partially welded at some stage due to a temporary short when a filament has blown.
Have you replaced any relays with a new one?
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I agree with Gary, sounds like a faulty headlight relay, maybe a broken return spring?
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Or the headlight cutout switch on the back of the starter button. Try some contact cleaner/lube in there.
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Or the headlight cutout switch on the back of the starter button. Try some contact cleaner/lube in there.
Good thought.
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I have to agree with Gadget and STeveo, it may be just dirty contacts.
But, great work there Winston on doing a very detailed analysis :thumbs
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Hi everyone ,
Well here is the latest news.
The problem appears to be solved, but you would be lucky to find a solution so easily.
The remedy, This is what I did.
firstly remove all of the plastic
I inspected all of the accessible wiring and connectors for obvious signs of chafing, bad connections, overheating , etc, etc, Nothing found, everything appeared to be spicky clean and in good condition.
I back probed all available earthing points to check continuity to chassis earth. All ok, and no signs of bad connections , , both sides, and or any overheating at the connectors.Nothing found.
I checked all fuses, and relays for integrity of operation , both by substitution with a known good item and also by bench testing of the original units.
In my initial analysis of the problem it was apparent that the motor control relay (shut down relay) was holding on when the ignition switch was turned off.
However I persisted in checking all of the relays , including the start relay and then cleaning the right hand handle bar stop and run and the start switches.
The initial problem still persisted.
During this process I monitored the engine control relay activation feed from the ignition switch. The red/black wire.
With the ignition switch in the on position the voltage at the relay measured 11.6 volts
I thought that this was a little low as the battery voltage at that time was in excess if 12.6 volts.
Then I turned the ignition off and the voltage at the relay dropped slightly to 10.6 volts.Something strange here as it should have dropped to zero volts with the ignition off.
This meant that the relay was still energized and supplying full power to its dependent circuits.
On shorting the red /black wire to chassis earth there was a bit of a spark and the headlights and dash display extinguished when the relay dropped out and did not re energize.
Something strange here I thought.
The next step was to uncouple the ignition switch connector ,4 wires plug just behind the left hand fork and unplug the engine stop relay, then I checked the red /black wire for continuity, all ok there , then I checked for resistance to chassis earth , this showed a direct short , zero ohms resistance to earth, Something strange here thought I, this is not good.
A few minute later a a new substitute wiring harness was fabricated to bypass the suspected short circuit to chassis earth that the red/black wire was showing.
And when plugged into the connector for the ignition switch and the other end to the motor control relay, and the ignition switch turned on and the starter activated the motor started and ran as normal , as well as all of the dashboard functions were as normal and when the ignition was turned off the motor shut down as it should and the head lights , dash light and functions etc, operated as normal.
It seems that my problem is solved.
I will have to reassemble the bike ,(plastic's etc), and then go for a road test. just to make certain that everything is ok, but I do not think that there will be any problems now.
A half a dozen energize , start , stop , on ,of ,cycles of operation whilst on the stand and still in the garage did not show any problems when I checked all of the operational systems that I could think of, So now I have my fingers crossed.
Please wish me luck.
cheers to all,
Winston66,
Northampton , Western Australia
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:thumb the old wire must be damaged somewhere in the loom and tracking to earth.
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Awesome work mate :hatwave and as requested... Good luck ;-*
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Strewth. That's persistence paid off for you!
Well done finding that weird fault. ++
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Good work. :thumb
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great fault finding skills at work there, well done :thumb