'06 Won't Start

[huchieglide]

mfletch, your situation looks very similar to mine. Except you don't have the extended warranty. I researched this forum and saw the posts by dcarver, airhead, and a couple of others. Since I had to wait a week or so to get appointment to have bike looked at I lifted the tank and saw the melted plastic. Since my bike was still on the trailer, I left it apart and showed the meltdown to the service tech. I think this sped up my diagnosis and repair. Not sure how it would have gone if not for this forums information and I just went to the dealer and let them do all the research.

After fidling with this while bike was still at home on trailer my bike did finally restart. So now I have an intermitent electrical problem, not what I want to be travelling the back roads with. Dealer said they could clean and grease the connector but felt it would reoccur. The service tech called and said Yamaha had authorized a new harness under warranty. I wonder if the new harness has been reengineered(made more durable).

Good luck, since you are not under warranty and it sounds like you have a trusted mechanic, you may want get a new harness and let him install it. A side by side comparison would be interesting.

Like you this problem burned through a week of preplanned vacation riding. :mellow:

 

[Nosecone]

decarver---you mention multiple spider grounds in the FJR wiring harness. I have found 4 on my 06 AE under the heat shield, left front, right front, and two left rear. I disassembled them and they were all clean and the housings OK. I did put dielectric grease on them though. My point here is I recall someone posted that there were 6 spider ground connectors.

Where are the other two?

I did find the left front one was positioned such that it was in contact with the frame. I know the frame gets hot and wonder if has caused some of the problems with this particular ground connector. Mine was OK but I did reposition it and added a piece of insulation between it and the frame.

BTW---my AE has 37+K miles on the odo and so far, knock on wood, zero problems.

John

 

[mfletch69]

Update....the FJR was towed to my mechanic last week and he disconnected the tip over switch to see if that was the problem. No go. :angry2: So now I am choosing the nuclear option and having him replace both the main and sub wiring harnesses. Probably going to run $1,000 before it is over with.

Meanwhile, I am enjoying the '79 CX500c B)

 

[Mcgyver74]

Meanwhile, I am enjoying the '79 CX500c B)

Wow does that bring back memories, my very first street bike was a 79 CX500c *(Even the same colors)*

 

[mfletch69]

Wow does that bring back memories, my very first street bike was a 79 CX500c *(Even the same colors)*

Yeah...I just got it and it is exactly like the one I had when I was a kid.

Here I am in 1980 at 16 years old complete with Van Halen hat. It is a lot like going back and kissing your 1st girlfriend again.

 

[dcarver]

decarver---you mention multiple spider grounds in the FJR wiring harness. I have found 4 on my 06 AE under the heat shield, left front, right front, and two left rear. I disassembled them and they were all clean and the housings OK. I did put dielectric grease on them though. My point here is I recall someone posted that there were 6 spider ground connectors.Where are the other two?

I did find the left front one was positioned such that it was in contact with the frame. I know the frame gets hot and wonder if has caused some of the problems with this particular ground connector. Mine was OK but I did reposition it and added a piece of insulation between it and the frame.

BTW---my AE has 37+K miles on the odo and so far, knock on wood, zero problems.

John

I don't remember exactly where the other two are. I think I recall seeing one under the seat, air filter area and another in the sub harness in the nose cone. Once again, from memory - I'm sure others have exact locations.

 

[mfletch69]

UPDATE

My mechanic ordered a new wire harness & sub harness and installed them today. Upon inspection, the old harness showed the reported melted black cap at the spider ground under the front left side of the gas tank.

The bike cranked and he said he rode it....but now the ABS light stays on!!!

He is going back through the bike to try to figure that out.

It is logical to conclude that this is a result of a heartier ignition switch being installed about 3k miles ago. The next weak point in the system soon breaks down. My mechanic was disappointed to see that the replacement harness is identical to the old one. I have sent him the write up for the ignition relay install as a possible improvement. I am afraid this is going to be a continuing problem moving forward - until Yamaha does a recall...and it is unrealistic to own a Gen II without a warranty.

I have lost confidence in the bike at this point and will be buying a new '08 (with YES warranty) next week, unless he is able to figure out the problem. I have been thinking about some other bikes but I just love the AE.

 

[dcarver]

I have lost confidence in the bike at this point and will be buying a new '08 (with YES warranty) next week, unless he is able to figure out the problem. I have been thinking about some other bikes but I just love the AE.

Any corrective actions taken? Run all accessories ground wire back direct to battery so as to not carry the current through the stock loom?

Use dielectric grease on all spider grounds?

Pray to the YamaGods it doesn't happen again?

I'm glad you're staying with the brand, whether new or 'fixing' the old girl..

 

[mfletch69]

We are trying the dieelectric grease. I am already using a fused power block under the seat for accessories. I have just about had it with the whole thing though.

 

[huchieglide]

I understand your lost confidence. Not being able to figure out the actual cause of the meltdown is frustrating. Why? And will it occur again? Did I do something to the bike to cause this even though I ran my accesories through a fuse block to the battery? Was the new ignition switch the culpret? Who knows. I have put 2500 miles on my bike since the harness repair without any incident. I just had the valves checked and the mechanic checked the grounding points and said all looked good. I will keep going with the 06 for now and hope all is well.

Good luck with your pursuit of an answer your harness failure. Maybe your mechanic can pinpoint something. Otherwise enjoy the new 08 you have your eyes on. Hopefully Yamaha has improved said parts on later models.

 

[git-r-dan]

I go tomorrow to pick up my bike after the ignition switch recall and cam tensioner replaced. gulp :blink:

 

[Shane Stump]

UPDATE
My mechanic ordered a new wire harness & sub harness and installed them today. Upon inspection, the old harness showed the reported melted black cap at the spider ground under the front left side of the gas tank.

The bike cranked and he said he rode it....but now the ABS light stays on!!!

He is going back through the bike to try to figure that out.

It is logical to conclude that this is a result of a heartier ignition switch being installed about 3k miles ago. The next weak point in the system soon breaks down. My mechanic was disappointed to see that the replacement harness is identical to the old one. I have sent him the write up for the ignition relay install as a possible improvement. I am afraid this is going to be a continuing problem moving forward - until Yamaha does a recall...and it is unrealistic to own a Gen II without a warranty.

I have lost confidence in the bike at this point and will be buying a new '08 (with YES warranty) next week, unless he is able to figure out the problem. I have been thinking about some other bikes but I just love the AE.

M,

I honestly understand your pain. Even having a GEN II bike with a warranty doesn't allow one much peace. I am getting ready to go for a day ride on my new BMW 1300 GT! It was so nice going on vacation without having to fuss over the FJR - in fact Sandi & Cassie mentioned that I only mentioned the FJR once in the last 3 weeks and it was a joke when I saw a Yamaha in Germany on a flatbed (it wasn't a FJR)!

Again, don't let it consume a lot of time of your near life like I did - it isn't worth it!

Best regards,

Shane