Sometimes you think the worst and its something so simple

Energy One
Twisted

Twisted

Well-Known Member
Well I was having headlight problems the past couple days, every one in a while the high beam indicator would come on for no reason while riding then go out. Then yesterday it was going crazy, would go on, then off, then start blinking and when I got home I had no headlight. So I opened up the headlight housing to find some rewiring, the plug grounded to the housing and a thinner ground coming out of the harness completely melted. It had already been upgraded to the ceramic plug but no mater what I tried I could not get it working. And I had a bunch of blinking light on the ehc, so I now I'm thinking a short somewhere or my ehc is going. Even tested the bulb hard wired to the battery, power to one side lit it up but power to the second terminal had nothing but at the time thought nothing of it, bulb works. Today when I got home I checked a few more things and decided to pull the tank to check the harness connector to find the plug was gone and they were spliced together but the black ground had been cut under the tank and wasn't even in use. So the melted ground was not even doing anything and must have been melted from the previous repair. So I went back the bulb that only lit on one terminal and figured I'd get another to rule it out and go figure it was the f**cking bulb the whole time. Put it back together and all seems well, so as they say start with the simple stuff first!!!!
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Sorry, I am still a little bit confused....is there a new ground wire back to the EHC?

The one under the tank isn't in use so where is the ground? Just to the headlight housing?
 
Twisted

Twisted

Well-Known Member
Th3InfamousI said:
Sorry, I am still a little bit confused....is there a new ground wire back to the EHC?

The one under the tank isn't in use so where is the ground? Just to the headlight housing?
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Yeah, that's how it was rewired, think I should re hook up the ground to the ehc? Seems to be working this way

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Th3InfamousI

Th3InfamousI

Administrator
Staff member
Twisted said:
Yeah, that's how it was rewired, think I should re hook up the ground to the ehc? Seems to be working this way

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Problem is, it must have been cut for a reason, maybe a short in the backbone?

I'd say ideally you run a new ground back to the EHC but you'll never find the right ground wire back on the EHC. Unless you want to de-pin it at the D-SUB connector. You could run a dedicated ground back to your battery from the JST under the tank, just run a new 22 gauge wire down the backbone. I had to do that for the front left turn signal before.

The flickering on that High Beam indicator is usually due to a grounding issue. The headlight bucket kinda sucks for a ground, usually the inside has flaking chrome chips but you should be okay as long as you have it attached pretty well inside that bucket.

Up to you really if your feeling frisky one day run the ground! Otherwise Ride her till she dies
 
Nukeranger

Nukeranger

Nukeranger
:old2: Good job and thanks for sharing. They always say there's trouble in "troubleshooting":oldsmile: I just don't understand why we make things more difficult than it needs to be.......:chopper:
 
Twisted

Twisted

Well-Known Member
Th3InfamousI said:
Problem is, it must have been cut for a reason, maybe a short in the backbone?

I'd say ideally you run a new ground back to the EHC but you'll never find the right ground wire back on the EHC. Unless you want to de-pin it at the D-SUB connector. You could run a dedicated ground back to your battery from the JST under the tank, just run a new 22 gauge wire down the backbone. I had to do that for the front left turn signal before.

The flickering on that High Beam indicator is usually due to a grounding issue. The headlight bucket kinda sucks for a ground, usually the inside has flaking chrome chips but you should be okay as long as you have it attached pretty well inside that bucket.

Up to you really if your feeling frisky one day run the ground! Otherwise Ride her till she dies
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I was a little confused too when I saw the ground bolted to the the headlight housing, don't thing anywhere on the front end is the best place for a solid ground due to the neck bearings and grease. But it's working for now so I'll run with it till I have time to redo it. Judging by the original ground being melted all the way back till it enters the harness tells me something wasn't right so I really don't want to try to reattach it.
I have some clutch issues I have to attend to first anyway, somethings not right on takeoff. It was so bad that if you gave it too much throttle it would either stall or buck, I adjusted the clutch which was way out of adjustment and it's much better but still not right, have to take off easy to be smooth. Gotta get some gaskets and open the primary and check thing out. But that may be a whole new discussion.
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
The gasket on 05+ is very reusable I bought a spare a few years ago and haven't needed it. Probably had the primary off 5X. You'll see when you open it.

Just an issue at take off or is it slipping if you get on it in gears too?

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Twisted

Twisted

Well-Known Member
Th3InfamousI said:
The gasket on 05+ is very reusable I bought a spare a few years ago and haven't needed it. Probably had the primary off 5X. You'll see when you open it.

Just an issue at take off or is it slipping if you get on it in gears too?

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That's good to know, maybe I'll pull it this weekend then. Yeah seems to be only on take off, once it's going shifting is fine. There's always been a good clunk going from neutral to first,and sometimes a little jump. And always a noticable clunk between gears but that seems about normal. The clutch was way out, had to turn it in a couple turns before I felt any resistance, then backed it out 1/4 turn, much better but still not right. Gonna start by pulling the primary, and taking a look at eveything. Bike has 11,000 on it don't know if the clutch is going, it's low on primary fluid, or maybe something else like the clutch basket or something.

Oh and haven't really got on it since I noticed the problems so can't say if it's slipping under heavy throttle
 
Twisted

Twisted

Well-Known Member
And sometimes you think it's something simple like a clutch adjustment that's causing problems and end up pulling the whole primary and clutch to find a broken clutch basket. F**K!!!


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Rickman07

Rickman07

Member
I just recently thought the same thing just an adjustment ended up being the clutch basket nut came off and a the primary case full of metal shavings in the oil lucky was be to salvage everything but it was a process cleaning it all out
 
Twisted

Twisted

Well-Known Member
Rickman07 said:
I just recently thought the same thing just an adjustment ended up being the clutch basket nut came off and a the primary case full of metal shavings in the oil lucky was be to salvage everything but it was a process cleaning it all out
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I was hoping it was just the nut but it was tight so figured I'd better pull it, good thing I caught it early before more damage was done.

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