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Cutty72
Posted on Saturday, April 06, 2013 - 12:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok so I came back last night after a ride, and as I was parking my bike, it just died on me. Turned the key off, then on again and it fired right up. Ran for about 10 seconds, then died again. Both times when it died, the headlights went out also.
After it died the second time, the fuel pump no longer kicks in, headlights don't come on, and I get nothing at the starter button.

All the fuses are good and the battery is new. I'm going to pull the EBR ECM and put the stock one back in after class today and see if that helps. If not, I'm at a loss...

Any ideas? Sadly I left my repair manual at home, and I have limited tools. Any help is appreciated!
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Two_seasons
Posted on Saturday, April 06, 2013 - 01:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Google Buell 1125r forum, the link at the top of this page.

Search for Zac4mac.

Zac had a problem with his ignition switch wiring harness and that in turn broke some of the wires off at the ignition switch.

It seems that the harness is really tight through the fairing area where it feeds the ignition switch.

Zac carved off some of the fairing (a tiny bit) and all has been well for quite some time with his bike.

Move your wiring harness as it connects to the ignition switch in the opposite direction to how it sits now. If it starts and runs, then maybe the wiring at the ignition switch is breaking.
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Imblasted
Posted on Saturday, April 06, 2013 - 01:01 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Try wiggling the key see if your headlight comes back on. Sometimes my headlight doesn't come on and after I turn the key off and on it works or I just wiggle the key
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Zac4mac
Posted on Saturday, April 06, 2013 - 01:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Try moving the handlebars with the key on.
If you get intermittent power, look at the wiring behind the keyswitch.

I have an 08 R and have had to re-solder the wiring twice.

<edit>A little more info on this thread -
http://www.badweatherbikers.com/buell/messages/290431/708583.html?1365175325

Z

(Message edited by zac4mac on April 06, 2013)
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Cutty72
Posted on Saturday, April 06, 2013 - 04:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Zac wins. Thanks man, I'll have to tear into it tonight (if time permits) and see what I need to fix it. At least get the wiring solid so I can ride until I get home to "modify" the fairing stay like you did.
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Cutty72
Posted on Saturday, April 06, 2013 - 05:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Forgot to ask, does the ignition come apart to get at the wires to solder them? Or what is the best way?
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Mcelhaney14
Posted on Saturday, April 06, 2013 - 05:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Remove the switch, you will need a T-45 safety torx for this. The switch itself snaps together, you will have to undo those to get at the wires. Just take your time and you should be fine.
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Zac4mac
Posted on Saturday, April 06, 2013 - 09:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Exactly

The hard part is getting the switch off.
I drilled a hole in a T-45...

The soldering is easy, a basic pad connection on the switch.
Pre-tin the wire and clean the pad to keep solder wicking to a minimum. get in and out as fast as you can.
Wrap the wiring in tape or something to spread out the forces. Ty-raps are a big help too...

If you don't take material off the fairing stay, it will happen again. IMO.
Just too much strain @ lock-to-lock.

Z

(Message edited by zac4mac on April 06, 2013)
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Cutty72
Posted on Saturday, April 06, 2013 - 10:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well I got it soldered back together. One wire was completely broken off, and another was about half way there.
I don't have a grinder or dremel with me as I'm away from home. (picked up a cheap soldering iron at home depot) so I just pulled as much of the wires as I could up above the stay. It seems to work, no more pulling on the wires from the ignition, but we'll see how it works as I put miles on it.
For now, I'm just glad that I'm mobile again and was able to fix it myself in the parking lot!
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Dannybuell
Posted on Sunday, April 07, 2013 - 11:32 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Woooooooooo WHoooooooo
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Cutty72
Posted on Tuesday, April 09, 2013 - 01:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

And went for a ride on some of these AWESOME TN backroads with another guy from my class. Have to say I was impressed. He is on a HD Fat Boy Low, and managed to almost keep me in sight the whole time.
That boy was RIDING that pig! Needless to say his floorboards are a bit sharper.
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