Dave wrote on 10/31/13 at 09:27:04:The wiring harness under the tank connects to the left and right handlebar electrical controls, to the coil, to the decompression solenoid, to the horn, to the speedometer cluster, to the horn, headlights, front turn signals......lots of stuff. The most common break in this area is the left handlebar wiring harness into the headlight, and often it is associated with the failure of the headlight low or high beam.....or a short that blows fuses.
The OP really needs to take the tank off and start looking at wires.
Thank you!
I really needed that encouragement to take it to the next level. I don't really have a background in anything besides changing oil on my Honda... so this was lots of fun (aside from the temporary despair and frustration).
I followed clymer's manual and took the tank off. It was really stuck on the two little rubber pucks that hold it up. I almost just gave up, but at the last moment in a bit of anger I really started thrashing around with the tank and it just came free! I don't think it's ever been taken off since it was built in 2004.
so for a moment I felt like a boss. I started looking at all the wires, I even cut open some of the black protector tubes... and everything was checking out. No burn marks. nothing out of place. With the tank disconnected and on the ground I put the key in the ignition and everything lit up. The bike even turned over, then I immediately turned it off-- vaccume tube, fuel line, and the California edition hose all disconnected, I didn't want to wreck anything.
At this point I was nice and down again. "dude, I don't know what I'm doing.... but I'm at least I'm trying"
I stepped over and started looking at the gas tank. I was almost finished chasing the wires in the cluster when I found the spot. Man I was happy. Heres a picture.
basically I just cut out the burned part and re-spliced it and wrapped it in hella electrical tape. I also checked the other blue wire with color distortion, cutting through the plastic with a razor. The copper looked good so I wrapped it all up again. wrapped all the suspect wires with more vinyl and then wrapped them all together like the black tube I had to cut through. Put it all back together.
BOOM! Back on the road! The gas feels old, but I'll ride through it in a week or so.
thanks again everyone. I learned a lot about current and electricity and lightbulbs (and I'm very glad I didn't have to rely on my shoddy handle on it hahaha!)