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Message started by B1-66er on 05/01/11 at 06:49:26

Title: Need help, wiring issues
Post by B1-66er on 05/01/11 at 06:49:26

Was putting the bike back together yesterday and I reconnected the battery and turned the key to check things. Then smoke came pouring out from under the tank. I pulled the tank off and there is a group of four wires(two orange, one orange/blue, and one green) that are all melted together. I'm pretty sure they just go to a relay. I can't find anything in the wiring diagram that makes sense. Anyone have any idea what they are and what might have caused the problem? Bike is an 88.

Thanks

Title: Re: Need help, wiring issues
Post by Routy on 05/01/11 at 06:58:04

Putting the bike back together,.....meaning what ?

One thing is for certain, you have a "short circuit" to ground,....meaning that somewhere the positive and negative got together,......meaning that a hot wire got connected to either a ground wire, or the frame.
I think I would start start looking at what you "put back together"

Title: Re: Need help, wiring issues
Post by B1-66er on 05/01/11 at 07:50:11

I put the tank back on.

I did mess with the wiring for there turn signal and headlight switches, but I had turned the key on at least twenty times since doing that.

I think maybe one of the wires just got pinched and grounded out.

Do you have any idea if that's a relay?

Title: Re: Need help, wiring issues
Post by verslagen1 on 05/01/11 at 08:38:21

Well if clymers color coding is correct, then the orange/blue and the green would be the side stand relay. The orange is hot and runs everywhere.

Title: Re: Need help, wiring issues
Post by B1-66er on 05/01/11 at 09:17:52

I was thinking that too, but the clymers only has three wires going to the relay, that's what confused me.

How would I go about bypassing that if I just want to eliminate it?

Title: Re: Need help, wiring issues
Post by verslagen1 on 05/01/11 at 09:44:57

where is the relay?

and how big are the wires?

Title: Re: Need help, wiring issues
Post by justin_o_guy2 on 05/01/11 at 10:13:56

Find damaged wires, remove, replace, check with VOM before reconnecting battery. IF theres still a problem after running the wires where they Have to Go in order to run the bike,, then you can fix it, fair chance ya peenched a warr & started a high speed electron transferal system, which created intense heat,,,, Dont be doin that!

Title: Re: Need help, wiring issues
Post by B1-66er on 05/01/11 at 10:23:30

Relay is under left side of tank. It's in a rubber boot thing that slides onto a the frame to hold it in place.

Title: Re: Need help, wiring issues
Post by verslagen1 on 05/01/11 at 10:45:11

yeah, think that's the sidestand relay.

Title: Re: Need help, wiring issues
Post by verslagen1 on 05/01/11 at 10:50:53

SSM shows 4 wires for a '96
green, orange, orange/blue, orange

Title: Re: Need help, wiring issues
Post by Serowbot on 05/01/11 at 11:00:59

I had an under-seat fire (no, not that... :-?...), and the source was where the wiring was the most burnt...
Follow the trail of destruction... ;)...

Title: Re: Need help, wiring issues
Post by B1-66er on 05/01/11 at 11:20:23

Does anyone know what I'd have to do to eliminate the relay and switch?

Also, would those wires burning keep the lights from getting power, or do you think I blew the fuse as well?

Title: Re: Need help, wiring issues
Post by justin_o_guy2 on 05/01/11 at 11:27:55

7C0F1308085B4C3E0 wrote:

Does anyone know what I'd have to do to eliminate the relay and switch?

Also, would those wires burning keep the lights from getting power, or do you think I blew the fuse as well?

You gotta look t the fuses to now,,

Title: Re: Need help, wiring issues
Post by verslagen1 on 05/01/11 at 11:34:09

The sidestand switch is not extremely important, but if you threw it in to a left hand turn with it down it'll either go up very quickly or toss you on yer biscuits. just saying is all.

if it's just the relay you're cutting out or the circuitry?

short the orange to orange/blue. cut the green.

circuitry will take more looking at.

Title: Re: Need help, wiring issues
Post by B1-66er on 05/01/11 at 11:53:53

I just wanted any easy fix without doing more wiring. But if I gotta jump wires, I'll just run new ones and keep the switch.

Title: Re: Need help, wiring issues
Post by verslagen1 on 05/01/11 at 13:23:18

Then a temporary fix would be to pull the relay and put a paper clip to jump the orange to orange/blue.

But the question still is, where's it shorted?

I'd pull the relay out and turn the key.
still blowing fuse? disconnect the kickstand switch under the seat.

Title: Re: Need help, wiring issues
Post by B1-66er on 05/01/11 at 14:37:24

I'm pretty sure that the wiring got pinched and hit the frame.

Title: Re: Need help, wiring issues
Post by justin_o_guy2 on 05/01/11 at 17:21:14

592A362D2D7E691B0 wrote:

I'm pretty sure that the wiring got pinched and hit the frame.

whoda guessed?

Title: Re: Need help, wiring issues
Post by B1-66er on 05/20/11 at 05:39:12

Well I feel like an idiot. So the guy that had the bike before me eliminated the killswitch and wired a tiny little push button for the starter. Well when I put that back on, one of the tabs was hitting the switch housing and grounding out. I decided to just eliminate the kickstand switch and wire in a new killswitch.

My question is this: How would I go about wiring a killswitch?

Thanks