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General Category >> Rubber Side Down! >> In desperate need!
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Message started by ashkun on 07/14/10 at 16:55:34

Title: In desperate need!
Post by ashkun on 07/14/10 at 16:55:34

Hi folks,

One of my wires shorted against the gas tank and melted a good number of wires in the main harness. I have a 1995 and the clymers manual showed that this was the ONLY year different than those older or newer models.

New OEM parts are discontinued for my year, and recyclers put a call out nationwide to no avail. I took my chance with a 2001 s40 harness off ebay knowing I could do some minor mods if needed. I got it today and too many plugs are different sizes and male/females are switched not to mention this one has smaller gauge wire.

Why am I in desperate need? I start grad school in a month (plus get married in September) so my buddies planned a 3 week ride/camping trip as sort of a last hurrah. We were supposed to leave this Friday.

Anyone have a source for the main harness? or even any ideas? It would be too risky for me to try and fix the current one or mod this newer one.

Thanks
:'(

Title: Re: In desperate need!
Post by thumperclone on 07/14/10 at 17:25:59

one wire burnt a number of other wires & the (a) fuse didn't blow?

get a volt ohm meter and "ring out" (check)every wire for a "fault"or short both ways > & <
take your time be persestint
then try
butt splicing color to color with crimp on splicers...
get a couple of 5 amp or less fuss fuss in case you missed something..

think you (or?) pinched a wire putting the tank back on..

Title: Re: In desperate need!
Post by Serowbot on 07/14/10 at 17:41:06

I had an LED running light bulb short out and lost about 6ft of wiring under the seat, up to the tank... had to replace about 6 wires... darn fuse took it's time blowing...
Cut and splice,... cut and splice... it's been okay since...

Title: Re: In desperate need!
Post by ashkun on 07/14/10 at 17:49:16

I would cut and splice if it weren't for that one wire melting the insulation of its own and three surrounding wires. The four have now become one wire.

Two of the plugs are melted beyond repair. The fuse blew once a while ago. Replaced it with another 20A and it was fine for a week. Then the next time it blew any replacement would blow instantly and that's when I took the tank off to see the mess that happened.

Title: Re: In desperate need!
Post by Serowbot on 07/14/10 at 17:55:33

Yup,.. you have to backtrack past all the melty and brittle wire,... toss it all, and work your way back...
...easier for me than a full wiring harness replacement...
..but still a bugger...

Title: Re: In desperate need!
Post by verslagen1 on 07/14/10 at 20:07:46

72607B78667D130 wrote:

This is why I said to the last couple of guys to dig into it.

Title: Re: In desperate need!
Post by justin_o_guy2 on 07/14/10 at 23:50:30

A wiring harness connector can be had at a junkyard. Cut the harness off on both sides of the connector long enough to solve the problem or just hack a coup0le of connectors ou w/ enough wires in them to be able to wire them into the wiring on the bike. Some tail lamp connectors have 4 in them, maybe more, but I cant see why..Replacemenst dont have to be Suzuki.

Title: Re: In desperate need!
Post by kevinphan on 07/15/10 at 03:54:59

If you can circle which connectors you need from a wiring diagram let me know and I'll see if I still have it. You can have it free of charge, if it's compatible

Title: Re: In desperate need!
Post by Digger on 07/15/10 at 21:21:56

Here is a good source for the connectors on our bikes (at least for mine (see signature)):

http://www.vintageconnections.com/

The owner is really helpful and knowledgeable. I've had nothing but positive experiences with this company.

IHTH!