Another EWS warning :(

[MickF]

Thanks a million. It's frustrating when there's nothing obvious showing up. I can just imagine I will have it sorted and I will either find or have my manual handed back to me!! I was going to order another Haynes manual but by the time it gets here I will have either found mine or, hopefully, found the problem.

 

[Santa-2512]

Right ,

according to Mr Haynes

The Immobiliser antenna has 4 wires

Blue / White A twisted pair ( Yellow / White - Yellow / Brown ) & Green / Black

These run in order L/R to the ZFE pins 57 (55 43) 8

The big problem is that they bring everything into the loom in one big branch under the beak / headstock

I removed

Screen / Kombi / Headlamp / Beak / Tank panel L / Tank panel R / Tank panel top / Tank -

Although you may not need to remove tank top

& moved the ZFE out of the way.

From there i started at the EWS and stripped the wrapping from the loom back to the big branch - nothing found

So then started on the big branch - which is where i found the broken wire -

You may end up going right back to the ZFE, but in reality you wont -

Wires dont break in static areas, they break where they flex or chafe.

the only areas where thay chafe or flex is in the headstock area.

I didnt think it possible myself, but on seeing the break its obvious - your only talking about 1-2mm of movement, but

over the amount of times youve moved the handlebars since 2006 - thats enough

the other way to hone in on an area, is each time you cut a length of harness wrapping away, flex the wires / turn the

handlebars and see if the problem comes and goes

Sounds like your in the home straight its only going to be one of those four wires

also check to see that the cable isnt over tight at the ring antenna,

it could be its pulling the connector apart and giving the failure, althogu id say it was highly unlikley.

( given that you can induce it by flexing the harness)


Edit if the break is in the twisted pair - your need to retwist any cable you replace - theo tothers can just be a straight splice / join )

 

[MickF]

Thanks very much for your guidance. Hopefully, I will get to have a longer look at it tomorrow when I get home from work. I have already isolated and checked the aboe four wire from antenna. I may just need to go further into the loom. You have made my search much more realistic by having given me the terminationof the wires. I will use my meter and check for continuity. Thanks again

 

[MickF]

I've only been able to have a quick look today but I have found this broken wire in the main loom. It wasn't obviously broken and took a bit of unwinding to actually see it. There appears to be at least a second wire, if not more, to be found and repaired. It's amazing how they can all seem to go at the one time?

 

[Santa-2512]

I've only been able to have a quick look today but I have found this broken wire in the main loom. It wasn't obviously broken and took a bit of unwinding to actually see it. There appears to be at least a second wire, if not more, to be found and repaired. It's amazing how they can all seem to go at the one time?

Right the twisted pair White / Brown & White / Black are used in several locations with the loom -

They are part of the Can Hi & Can Lo side of things -

Starting from the CEU -Central Electronic Unit there is a link to the Engine Control Unit then to the starting & charging side - there is a link to the

Anti Theft Unit a link to the Instruments & Trip computer and finally a link to the ABS unit

so which system that particular wire is from is anyone guess

The other question is The Green / Yellow is it a previous repair ?? if not, likewise to the WBr - WBl the Gy wire covers a number of components

I'd fix the broken one first and check the results - if no better, then you still need to go hunting

 

[MickF]

I forgot about the other wire I had fixed. I used ordinary pvc tape as a tempory measure in case I had to do longer stretches. I actually can't find my supply of heat shrink at the moment . My Tesa Wire Harness Tape arrived this morning so hopfully I can find the remaing issue shortly and restore everything to original state.

 

[MickF]

The latest broken wire !! This one turned out to be a nightmare to locate. It's the push in connector for the ignition switch. There's a kink and apparantly broken wire inside the cable just as it enters the connector. Hopefully the piece can be bought on its own. Time to start looking.

 

[Santa-2512]

The latest broken wire !! This one turned out to be a nightmare to locate. It's the push in connector for the ignition switch. There's a kink and apparantly broken wire inside the cable just as it enters the connector. Hopefully the piece can be bought on its own. Time to start looking.

You can buy ready made repair harness leads from the mothership i'll have a look later

You can but just the individual pins via the bay again - later

 

[MickF]

My stubbornness has eventually paid off. I found a source for a new male plugin for ignition switch but it would take up to two weeks to arrive. I managed to open the connector quite easily and took out the pin with the defective wire. I soldered it and a bit of careful relocating should take away the flexing where I repaired it. Thanks to everyone for their assistance, particularly santa - 2512 who pointed me in the right direction from the start and showed great patience towards my sometimes silly questions. Re taping the loom and replacing all the parts will be a dawdle now

 

[Santa-2512]

Glad youve fixed it,

Mothership prices are eye watering for that repair harness.


I was going to suggest backing the pin out and seeing if you could do a repair etc.


The bigger question is ... does it work ie start ?

Is the EWS warning gone, and does it work in all handlebar positions ??

 

[MickF]

Done and dusted. I tried the various "new" connections I made to ensure they won't give up again too soon. If I get another 10 years out of it I will be delighted. I'm forty years motorcycling and it's the most reliable bike I've ever had. I have often thought of updating to an LC but my adage would be "if it's not broken, why try to fix it". This little setback wouldn't put me off the bike. Everything is now working as it should be. It may be just my imagination but it now appears to be more responsive after pressing the start button. It always seemed to be hesitant in starting. Happy days. Now, just a few days off and time to hit the road.

 

[Santa-2512]

Glad we could help