Electrical Problems

[Constant Mesh]

On the '06A schematic that connection is not clearly defined but it could be the connection shown below the headlights on the 2/2 wiring diagram.

The common returns for the headlights, the front turn signal/running lights, the horns, the windshield up/down controls, and windshield drive unit may all tie into the return bus at that problem termination.

The headlights are obviously a big continuous load -- about 10 amps.

 

[mikerider]

If true then why it caused the engine to stumble? There must be something else connected to it, no?

On the '06A schematic that connection is not clearly defined but it could be the connection shown below the headlights on the 2/2 wiring diagram.
The common returns for the headlights, the front turn signal/running lights, the horns, the windshield up/down controls, and windshield drive unit may all tie into the return bus at that problem termination.

The headlights are obviously a big continuous load -- about 10 amps.

 

[Silent]

I came up with my own solution. After checking the connector, I found that only 1 wire was connected to ground. The wire that's been getting hot enough to deform the plastic. So I soldered a wire to the top of the 6 pin strip and ran it back to B-. You can never have to much ground. I also packed the connector with dielectric grease. The bike runs fine with this extra ground. I'll give it some time and see if it's fixed or just masked.

 

[canyonman]

I just completed a bunch of over due maintenance items and had the bike in many pieces.

I went through and hit every connector on the damn bike with dielectric grease.

There are at least 6 or so of these grounding connections in the harness from one end of the bike to the other although the one in question seems to be the only one causing all the trouble.

Mine thankfully showed no signs of corrosion and hopefully now that I lubed them they won't

 

[Bill]

I just went through and checked all of mine this afternoon. Thankfully, every one of them looks like the motorcycle was assembled yesterday. I packed each with dielectric grease and put everything back together.

On my 2006, I have:

Audiovox Cruise Control

Garmin 2730

Motolights

J&M JMCB-2003 with Bluetooth

Fiaam Horns with a Randy Harness

Yamaha Heated Grips

Heat-Troller for my Gerbing's stuff

I use a Centech Fuse Panel that's mounted behind the rear seat and under the rear cowl

 

[thomasz]

well, share with your problem, You take your car to technology service

 

[lazbm]

After checking the connector, I found that only 1 wire was connected to ground. The wire that's been getting hot enough to deform the plastic.

Going through this thread and a related one (https://www.fjrforum.com/forum//index.php?showtopic=113632&st=0) I couldn't find any mention of where that return ground wire goes to. Meaning, where is it grounded - to some point on the frame, to some other coupler (sic), where?

Pardon me if I missed it.

 

[Silent]

I have no idea where that wire is grounded. The wires run back into the main wiring harness. My cure was to solder a wire to the ground strip and direct wire it to the battery.

 

[lazbm]

Thank you Ray.

I was wondering whether that end connection is weak thereby heating up this wire, which in turn heats up the coupler. In which case, there has to be some tell-tale sign of heating at that final grounding point too.

Maybe, someone like un4gvn, who has access to a removed harness, will be able to tell us where that final grounding point is for this coupler.

Just a theory.

 

[HJHFJR]

Thank you Ray.
I was wondering whether that end connection is weak thereby heating up this wire, which in turn heats up the coupler. In which case, there has to be some tell-tale sign of heating at that final grounding point too.

Maybe, someone like un4gvn, who has access to a removed harness, will be able to tell us where that final grounding point is for this coupler.

Just a theory.