| Author | Message | ||
     Etennuly |
My '06 Uly has taken to being a fair weather machine lately. About a week before I went to Daytona on it, I was riding in the rain. I got about twenty miles down the road when it died. Primary ignition still on, lights still on, instrument cluster still on, secondary ignition dead. I tried to restart, it would crank like nothing was wrong. Fuel pump on as normal. In about two minutes it fired right up and carried me about two miles, same thing. Waited another two minutes, same thing. I limped it to where I was going two miles at a time, about six fail events. Today, first time in rain since then. Twenty miles in it quits, same symptoms, same refire two miles and quit. I pushed it the last two hundred feet (down hill) into my driveway. Starter cranks very strong, new battery hooked up and tight, all lights and instrument on and good, fuel pump on. Engine quits as if key is shut off, but it is not, totally different restart than when the BAS died. Runs great when dry. Total engine quit, it did NOT sputter, as in not one coil bad or plug wire failure. Everything under the seat is dry. Wiggling key in switch didn't matter. I have checked and rechecked grounds that could be had without disassembly. Any ideas? | ||
| Mnrider |
Maybe crank sensor or coil. | ||
| Ikeman |
I had a similar problem but mine would just die and not even attempt to crank. All lights and gauges worked. Took 2 roadside strandings to eventually diagnose it as water collecting in the connector going to the cam position sensor (don't know the connector number off-hand). Tech thoroughly dried it out, packed it full of dielectric grease and never encountered the issue again. | ||
| Etennuly |
Thanks, down low seems like a good place to look. It seems to me that it would be in a place that would collect water or a bared wire that water helps short. I had been thinking about sneeking off to MBVI tomorrow. Looks like that is out.( I need to be working anyway) | ||
| Etennuly |
Well I didn't get anywhere with MBVI. I worked through the weekend. Finally got to look at the bike yesterday. The cam position sensor wires have been worn through in two places. The chin faring really kinks it where it comes up from the wire loom to the sensor. After taking the chin faring off I found the muffler bracket has worn into the wires even further than the chin faring. Looks like I need to figure out how to fix them. Maybe some heat shrink and a new sheath. Rerouting it some will help. I'm gonna try that photo bucket thing again later today. | ||
| Ourdee |
Photobucket is good once you get used to it. There is some stuff called liquid tape. It can be brushed onto wires, works like electrical tape when dry. I would still heatshrink over it. | ||
| Bienhoabob |
I've used that liquid tape when I found a crack on my spark plug boot, causing the bike to miss in the rain. I coated the boot with liquid tape. After 10,000 miles, some in hard rain, the bike has not missed a beat. Good stuff, that tape. (actually it's like white out for paper, but of a rubber compound) | ||
| Etennuly |
Interesting. The wires are just chaffed into them, not broken or anything. I will check into that liquid tape. I really don't want to cut the wires. Has anyone seen a heat shrink that will wrap around them rather than slide over? | ||
| 12x9sl |
I've used that liquid tape as well with heat shrink over it when the wife's heated grips started blowing fuses. Works great. | ||
| Hardlya |
Most electronics parts houses carry wrap on heat shrink tubing. Pretty handy when you don't want to cut the wires!! Also available is heat shrink tubing with encapsulation (once heat is applied) for the ultimate in weather proofing. | ||
| Wolfridgerider |
I'm starting to have some issues with the clock not keeping the correct time and the trip meter resetting itself to zero.... I hate electrical problems.... hope ya get it fixed Vern or you'll be on the blast! | ||
| Etennuly |
 So you know where I have been, eh? After getting wet the other day I have been Blasting around. I should have it fixed today. I want to find that wrap around shrink stuff. I had that cluster problem about six months ago, can't remember how I fixed it. Try searching in archives from back then for that problem. | ||
| Teeps |
Here you go: http://www.wiringproducts.com/index1.html (Message edited by TEEPS on April 01, 2009) | ||
| Etennuly |
Thanks for the help and suggestions all!  | ||
| Etennuly |
Closer inspection of the cam sensor wires show that they are warn about half way through. I am going to cut and solder them with heat shrink and a new sheath. I figured an inspection of all of the wires in the area under the right side covers was in order. I have found some rubbing on some to where if it were left there for another 36,000 miles they would likely be rubbing through, so I am moving them around a bit. My 77 connector has started to melt. I have checked it a couple of times in the past. This is the first sign of over heating. Since I am not changing the regulator at this time, I am going to cut and solder the joint. If I have to change the voltage regulator someday then I will buy the plug kit and install it. | ||
| Teeps |
Rather than solder the wires, use Heat Shrink Insulated Butt Splices like these http://www.wiringproducts.com/index1.html | ||
| Chrisrogers3 |
Etenuly, Hey this is the first I read this post, but it sounds like I have the EXACT same issue as you are having. I was headed from Colorado to Wisconsin on my Uly and about 30 miles into my trip it was doing the same thing. Rain and snow were a factor on the road and I barely got it back to WI. I have an appointment on tuesday to have Appleton HD look at it since it is still under warranty. I will let you know what they say, and if you find anything else out on your end let me know. Thanks, Chris | ||
| Sekalilgai |
Hey Vern just saw this...hope you got it fixed. Must take a closer look at my next oil change. I wonder if PTFE/Teflon coated tape on the stationary parts might help? | ||
| Etennuly |
You said "teflon coated tape"!!! Put it back together yesterday, it fired right up. Going to ride about 25 miles this morning. It went as described and everything went back the way I wanted it to. The oil pressure sensor wire was rubbing on a hard contact spot near the filter also. I moved all of them around to slightly different angles and used twice as many zip ties as well as double wrapping the sheath with electrical tape. It should be good! | ||
| Sekalilgai |
a new entry into the knowledge base!  | ||
| Mnrider |
Thanks for letting us know what you found.  | ||
| Etennuly |
 Here is where the muffler bracket ate through the cam sensor wires. | ||
| Etennuly |
 This is where the chin faring wore into them also. | ||
| Etennuly |
 "77" connector. Note melting on right pin and hole. | ||
| Etennuly |
 Cam sensor wires out of their sheath. Pardon my first successful attempt at posting pictures from Photo Bucket. Thank you Froggy! Your instructions were real close(my inability has been real big)  . | ||
| Adamd |
We should have a mechanical troubleshooting FAQ, but for sure add it to the KB. | ||
| 99savage |
Anybody brave enough to make suggestions for preventing the problem? Trim the faring?? | ||
| Etennuly |
I think simply moving the wires around will work. When I put it back together with twice as many zip ties, it looks much cleaner and fits inside the fairing much better. I will post a picture of that later. |
