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thought i'd start this thread to address this problem before tons of peeps start having failures. if you've taken your panels and hood off i'm sure one of the first things you noticed was all the wires that are unprotected, left hanging or routed so that they are rubbing to the point of shorting out. will post the problem areas i have found and if you have some please post them up, don't think one person could find all the points, there are many.
first is on the pro, the control switches in front of the gas cap, the wiring for this goes straight into the steering stem mount, mine had already wore a bare spot to the high beam. i bent the wiring coming out towards the rear and zip tied the harness to the fuel line on the fuel pump. you will have to remove the cowel to tape up the unprotected wires, two push pins and then the large nut around the gas cap removes it.
next spark plug wires. mine were zip tied together where one wire had the protective cover and below the cover on the second, this has rubbed the wire almost in half on the left side. the right side plug wire was routed over the water hose that goes into the top of the head, it had almost rubbed through on the clamp for the hose and the bolt on the aluminum fitting for the hose. these wires are molded to the coil, so coil and wire have to be replaced. reroute and protect wires where necessary. would suggest loom from coil to plug cap.
next power wiring for the coils. these are not protected for the last 3-4 inches, my left side coil had a spot rubbed bare on the red wire. caused from it rubbing on one of the coil mounting bolts. the adjoining white wire was almost bare. you could see where it had been arcing at the bare spot, also at the plastic plug connector for the wiring. taped all exposed wiring and rerouted away from mounting bolts. was just thinking maybe flipping the mounting bolts for the coils upsidedown so the extra exposed threads are not there to rub on. will have to check for clearance on this one.
next tps connection, they have zip tied the harness to where the wiring plugs into the tps itself. on mine the zip tie had fallen or was placed right at the bottom of the top half of the plug so it was not able to sit flush in the connection. remove zip tie, completely seat tps plug connection, relocate wiring harness zip tie.
next ecm wiring plug. this is located behind the oil res. bottle. the connection is very hard to get to "click" together and takes quite a bit of force. give the connection a good tug, if it comes apart makes sure the protective sealing boot on plug is straight and then replace into connection until you hear it "click"
next tapeing and protecting all exposed wires. this is quite a little project, seems at almost every connection there is 2-4 inches of unprotected wires. all these need to be wrapped for protection. every one is a short waiting to happen!!! i just started over by the oil res. bottle and worked my way around to the other side. also added zip ties where necessary to keep harness from rubbing in as many places as possible.
next the infamous oil injection line. the line from the res. bottle to the pump rubs on the aluminum plate. zip tie so bend is off aluminum.
if you have any other problem areas please post them up and how you cured the problem. this sled is awesome but i can see now that peeps are starting to get some miles on them these shorts are gonna start to cause several different problems. many can be avoided by a little preventive maintainence. i always say a few minutes of maintainence will save you hours of being broke down on the hill!!!
first is on the pro, the control switches in front of the gas cap, the wiring for this goes straight into the steering stem mount, mine had already wore a bare spot to the high beam. i bent the wiring coming out towards the rear and zip tied the harness to the fuel line on the fuel pump. you will have to remove the cowel to tape up the unprotected wires, two push pins and then the large nut around the gas cap removes it.
next spark plug wires. mine were zip tied together where one wire had the protective cover and below the cover on the second, this has rubbed the wire almost in half on the left side. the right side plug wire was routed over the water hose that goes into the top of the head, it had almost rubbed through on the clamp for the hose and the bolt on the aluminum fitting for the hose. these wires are molded to the coil, so coil and wire have to be replaced. reroute and protect wires where necessary. would suggest loom from coil to plug cap.
next power wiring for the coils. these are not protected for the last 3-4 inches, my left side coil had a spot rubbed bare on the red wire. caused from it rubbing on one of the coil mounting bolts. the adjoining white wire was almost bare. you could see where it had been arcing at the bare spot, also at the plastic plug connector for the wiring. taped all exposed wiring and rerouted away from mounting bolts. was just thinking maybe flipping the mounting bolts for the coils upsidedown so the extra exposed threads are not there to rub on. will have to check for clearance on this one.
next tps connection, they have zip tied the harness to where the wiring plugs into the tps itself. on mine the zip tie had fallen or was placed right at the bottom of the top half of the plug so it was not able to sit flush in the connection. remove zip tie, completely seat tps plug connection, relocate wiring harness zip tie.
next ecm wiring plug. this is located behind the oil res. bottle. the connection is very hard to get to "click" together and takes quite a bit of force. give the connection a good tug, if it comes apart makes sure the protective sealing boot on plug is straight and then replace into connection until you hear it "click"
next tapeing and protecting all exposed wires. this is quite a little project, seems at almost every connection there is 2-4 inches of unprotected wires. all these need to be wrapped for protection. every one is a short waiting to happen!!! i just started over by the oil res. bottle and worked my way around to the other side. also added zip ties where necessary to keep harness from rubbing in as many places as possible.
next the infamous oil injection line. the line from the res. bottle to the pump rubs on the aluminum plate. zip tie so bend is off aluminum.
if you have any other problem areas please post them up and how you cured the problem. this sled is awesome but i can see now that peeps are starting to get some miles on them these shorts are gonna start to cause several different problems. many can be avoided by a little preventive maintainence. i always say a few minutes of maintainence will save you hours of being broke down on the hill!!!
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