Wiring issues
Posted: Tue Dec 13, 2016 5:49 am
Hi guys, I thought I’d pass on this about the latest issue with my 1996 535cc Bullet. I had an intermittent lighting failure which I couldn’t track down in the ratsnest of wiring. Head lamp, tail light, pilot lights only kept failing (the flashers and stop light worked fine). I thought the bike was a UK import, but the UK wiring diagram materially mismatched. The “regular†wiring diagram also doesn’t wholly match but it is closer.
I eventually tracked the bad connection to the ammeter area where I discovered that, although the connection posts are solid brass, and the nuts are solid brass, the washers either side of the wire ring terminals were brass plated iron. So although they looked like brass from a cursory glance, the core of each washer was rusted and breaking the circuit.
And this is how it came from the factory, because I’ve owned the bike since 18.5kms – mind you it did last for ~20 years and ~15000kms.
Cheers, ChrisD.
I eventually tracked the bad connection to the ammeter area where I discovered that, although the connection posts are solid brass, and the nuts are solid brass, the washers either side of the wire ring terminals were brass plated iron. So although they looked like brass from a cursory glance, the core of each washer was rusted and breaking the circuit.
And this is how it came from the factory, because I’ve owned the bike since 18.5kms – mind you it did last for ~20 years and ~15000kms.
Cheers, ChrisD.