| Author | Message | ||
     Portero72 |
Are these two items on the same ground? Reason I ask is because at full right lock, the front brake switch fails to activate the brake light, and the headlights are cutting out during side to side sweep. Just to be sure, I changed the brake switch with a new one and got the same behavior. | ||
| Daddio |
Probably broken wires in the harness where it flexes next to the steering head, but it could be ground wires near the ground point on the front of the steering head. | ||
| Arry |
It looks like the brake lights have separate wiring, and only ground at the tail light, so you probably have more than one problem. Most likely where Daddio described. | ||
| Portero72 |
Definitely need some guidance here. I have the bike apart and insulation off the wires by the steering head, but cannot seem to pinpoint the issue. If I grab the entire bundle and wiggle, I can get the front brake light to flicker, but I cannot seem to locate the individual wire that is the issue. There are, of course, 5872 wires in there to play with. I do not have, nor would I be able to decipher, a wiring diagram. Anyone familiar with which wires control the front brake switch? FWIW, the major ground bundle behind the headlights does not appear to be the culprit. I can wiggle those all day, with no effect. | ||
| Etennuly |
If you are getting a flicker when you wiggle the wire bundle you have found the problem. Now you have to pin point it. Is this your new '09 Uly? Are there splices in the wire bundle where one wire goes in and three or so come out? There was a problem with the splicers on the '06 bikes that they could feel and look fine but be broken and still getting partial contact. They used a cold crimp with wax sealer in the ends. They have to be completely unbundled to find the problem. | ||
| Portero72 |
This is the 09 Uly, and I have spotted a couple splices with one in/two or more out. I have tried almost every wire I can find that appears to be a ground, I just cannot seem to pinpoint it. | ||
| Arry |
I've seen it posted on here before that the wires that flex at the steering head can break, but the insulation isn't broken. If you pull on individual wires, like your trying to stretch them, you may find the bad spot (as the insulation will stretch if the wire inside is broken). | ||
| Daddio |
What Arry describes is exactly what my '09 did on the low-beam, and although I haven't properly diagnosed yet, is what I fear is happening with my hi-beam. You'll have to gently separate the bundled wires, and see if by individually manipulating each wire, replicate the problem. A red with yellow stripe should be your brake light circuit wire, but you don't say whether the 'headlight' is the high, low, center 'euro' light or all three. | ||
| Portero72 |
Daddio- Thx for the tip on the brake circuit. The headlight in question was the low beam. | ||
| Daddio |
Happy to help, I'm just a guy with a service manual that has a wiring diagram. Did you get it fixed? | ||
| Portero72 |
Not yet. Have not had time to work on bikes this weekend. Any suggestions as to how to fix the broken wires? Not sure I want to stuff a bunch of butt connectors into an already tight area. | ||
| Daddio |
Find the break, work your way up and back an inch or so, and solder in and heat-shrink a splice of proper length of the right gauge of stranded wire. When you have the cowl cover off, watch how the wire loom works back and forth as you swing the handlebars, see if you can free up some of the movement so its not flexing an the steering head. You might need to snip a ziptie or two. | ||
| Portero72 |
Daddio- Thanks for the help and tips. Gonna dive into it after my spring break trip to the Ozarks....on the KTM! |
