Author Topic: Failure Waiting to Happen  (Read 222 times)

Online West Aussie Glen

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Failure Waiting to Happen
« on: January 19, 2020, 11:34:24 PM »
Some of you may remember thread:-

http://ozstoc.com/index.php?topic=13344.0

The problem turned out to be high resistance in one pin on the large multi pin connector behind the left hand fairing, see photo1.
The multi pin connector is where the wiring sub harness that goes to all the front lights and instrument panel joins the main harness.

This is the bike involved.
http://ozstoc.com/index.php?topic=13721.new#new

Well I am in the process of tidying up this connection.
After some testing and checking of available wiring schematics it would appear that this wire is the earth wire to the sub harness.
The best I can figure it out is that this wire goes from the multi pin connector to the yellow joiner in photos 2 and 3.
This joiner has another 13 wires going into it.
I think these are the earth wires from:-
Horn
Position Lights
Left Ind
Right Ind
Left H/L
Right H/L
Horn
Screen Up relay x 2
Screen Down Relay x 2
H/L Aiming Motor
Bank Angle Sensor

This means that the current from all of these is transmitted by the one single earth wire.
Has anybody had any experience with this yellow connector?
I want to open it and patch in another earth wire to reduce the load through it at the multi pin connector.

If my findings are correct please do not add any extra load to this sub harness and if you have the left hand fairing off check the multi pin connector for any sign of it over heating.


 
Glen
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Online West Aussie Glen

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Re: Failure Waiting to Happen
« Reply #1 on: January 20, 2020, 12:52:51 AM »
Found this on ST-Owners:-
"Ground wires are solid green and as the 1300 ages there have been increasing electrical ground issues in the front half of the bike. All device circuits forward of the engine lead to a common buss up and behind the RH headlight. It is yellow and combines a number of greens to a common green. From there the single green inside the wire loom runs to the white 24 pin connector above the LH cylinder head. There are a number of threads on corrosion and/or overheating at the yellow buss or at the 24 pin. If you continue to have odd or intermittent electrical issues including lighting or no start no fuel pump symptoms the ground circuits described bear scrutiny."

But couldn't find the other threads it mentions.
Glen
Safe Riding
Sold
1948 James 98cc 2 Speed, 1969 Suzuki A100-2
1970 Suzuki T250 Hustler, Honda CL100 (125cc)
Yamaha RD250C, 1985 Kawasaki GPZ250
BMW K75S, 78 Yamaha XS11
Yamaha Royal Star Tour Deluxe, 88 GL1500, 99 SE
GL1500
In the shed
85 Kawasaki  LTD250
88 GL1500 Outfit
08 ST1300
2013 GL1800
 
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Online Brock

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Re: Failure Waiting to Happen
« Reply #2 on: January 20, 2020, 01:00:20 AM »
That setup is never a good idea, those grounds should be connected directly to frame.
Brock
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Offline Gadget

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Re: Failure Waiting to Happen
« Reply #3 on: January 22, 2020, 12:25:47 PM »
That setup is never a good idea, those grounds should be connected directly to frame.
Yep. Shortest earth wires paths as physically possible.

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Offline Biggles

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Re: Failure Waiting to Happen
« Reply #4 on: January 22, 2020, 05:14:19 PM »
That setup is never a good idea, those grounds should be connected directly to frame.

Honda keeping its wiring looms simple.  To connect every service to frame individually would involve labour costs.
For the modern man who lives in the city, riding a bike might be one of the only ways to escape the humdrum monotony. To take off and ride. To be both at one with nature and one with the bike. To feel masculine. Adam Piggott

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Online West Aussie Glen

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Re: Failure Waiting to Happen
« Reply #5 on: January 28, 2020, 01:02:23 AM »
OK I got the end of the yellow cover open to expose the connecting bar.
Then soldered two wires to the connecting bar
Cabled tied the yellow cover closed and ran the two wires to the frame
Don't think there will be any more earthing problems with the new set up.
I have also remade the original connection bypassing the 24 pin plug.
Glen
Safe Riding
Sold
1948 James 98cc 2 Speed, 1969 Suzuki A100-2
1970 Suzuki T250 Hustler, Honda CL100 (125cc)
Yamaha RD250C, 1985 Kawasaki GPZ250
BMW K75S, 78 Yamaha XS11
Yamaha Royal Star Tour Deluxe, 88 GL1500, 99 SE
GL1500
In the shed
85 Kawasaki  LTD250
88 GL1500 Outfit
08 ST1300
2013 GL1800
 
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Offline Biggles

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Re: Failure Waiting to Happen
« Reply #6 on: January 28, 2020, 11:21:39 AM »
Yep.  Two core 240v electrical cable should be able to carry the load.  :grin
For the modern man who lives in the city, riding a bike might be one of the only ways to escape the humdrum monotony. To take off and ride. To be both at one with nature and one with the bike. To feel masculine. Adam Piggott

OzSTOC #16  STOC #6135  FarR #509  IBA #54927
 

Online Brock

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Re: Failure Waiting to Happen
« Reply #7 on: January 28, 2020, 11:23:03 AM »
That should do it...

 :beer :beer
Brock
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Online West Aussie Glen

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Re: Failure Waiting to Happen
« Reply #8 on: January 28, 2020, 11:46:10 AM »
Yep.  Two core 240v electrical cable should be able to carry the load.  :grin
Don't think it is 240v cable, came out of my  sidecar when I rewired it. More likely speaker cable but it doesn't have any positive or negative markings so may be 240.
Each core probably has twice the copper the the single honda wire has.
Should reduce voltage drop to headlights.
 
Glen
Safe Riding
Sold
1948 James 98cc 2 Speed, 1969 Suzuki A100-2
1970 Suzuki T250 Hustler, Honda CL100 (125cc)
Yamaha RD250C, 1985 Kawasaki GPZ250
BMW K75S, 78 Yamaha XS11
Yamaha Royal Star Tour Deluxe, 88 GL1500, 99 SE
GL1500
In the shed
85 Kawasaki  LTD250
88 GL1500 Outfit
08 ST1300
2013 GL1800