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By Kentish Man
#83570
:geek: <t>Hi to all. riding home from RE Kent Branch meeting, nearly home, was "making progress, lined up bike for left hand turning into side road, indicated, cranked her over and lost power, clocks and lights dimmed, engine misfired. Nearly fell off. <br/>
Kept engine running and limped home (100 yards).<br/>
Next day investigation showed with left indicator on, flasher unit is flashing in time as normal, but no indicators flashing, ammeter is swinging intime with flasher unit but full discharge . Right idicator is o.k.<br/>
Removed seat and unplugged lighting/indicator harness to rear of machine. Front left now working pulling normal current.<br/>
Removed rear light and unplugged indicators /stop/tail. plugged harness back in , original fault returned.<br/>
Made new harness using 0.75 mm 4C flex,cable tied to original harness. rewired left indicator/ right indicator/earth, and a extra earth to mudgaurd front fixing bolt . cut the original wires near the plug and crimped to them.<br/>
All working good now , but noticed another fault, Head /pilot/tail lights pulseing with indicators.<br/>
once again unplugged rear lighting harness, lights still pulseing. Have host's LED pilot bulb in front which is brilliant white, and that is really noticable flashing, also have host's 23watt indicator bulbs fitted as well ( do you kow you might have 10watt bulbs as standard?).<br/>
unplugged flasher unit bridged out to connections, could see lights dimming when selecting L/R indicators.<br/>
Bike has Motobatt glass matt battery fitted age unknown, i have had bike for nearly 2 years. charged battery with optimate, measured with multimeter at 12.3 volts. opened up headlight shell, checked for loose bad earth connections all looks good. i removed starter motor a year ago with accociated cableing, could it be just the battery????</t>
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By Wheaters
#83571
You mentioned that the ammeter goes to full deflection with the left side indicators selected on. A duff battery wouldn't do that. It sounds like a short circuit to the rear of the bike. Could the key be that the fault wasn't there when the seat was off the bike? Something getting trapped?
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By stinkwheel
#83573
That kind of misbehaviour sounds like an earth fault. Try temporarily taking a wire directly from one of the earths in the back of the headlamp to the battery negative and see if the problem goes away.
By Kentish Man
#83575
Hi to all again,
Wheaters,
Yes, problem was rear sub harness to back off bike, that's why I rewired with 4Core flex ( needed 5Core) so will rewire it again with maybe 7core trailer wire. am running 2 cables at the moment, original with stop/tail/earth and new 4 core flex with left indicator,right indicator, earth, and extra earth to mudguard bolt. That sorted that problem out.

Stinkwheel,
Looked at earthing from headlamp again , noticed the rubber cover was discoloured, pulled apart to find black burnt connection. cut this out and crimped using red 1.5mm through crimp. also installed extra earth as advised so two wires in one side, one in the other. ran wire to front down tube, just below the petrol tank. There are some 5mm threaded holes there so used them with a ring crimp.

So far so good.

Side lights on, indicators on, left and right, same problem lights pulse with flasher unit. Also side lights on, brake light on lights dim.


Gonna swap batteries with another bike, :idea:

Thanks for your help gentlemen.

:
By Kentish Man
#83648
Hi to all again,


Adrian, thanks for the link makes interesting reading, I quite like the Lucas style lamps.
Swapped Batteries with a brand new exide one from my Suzuki, problem still persists (was worth a try).
Swapped the 23w bulbs for the original 10w bulbs and flasher unit, problem still persists, put the 23w parts back in.
Ran an extra earth from front indicators to frame, again, problem still persists.
You will see in the pic, have fitted indicator warning buzzer, have just done this while the seat is off, it is not part of the problem.

Have not yet disconnected the flasher warning light yet.

:?
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