Well, I found the problem......

[JeffL]

Well, as of late I've had "minor" (aka, I hate you and want to drop you off a bridge) electrical problems with my bike. This all stems back to this: http://www.nestreetriders.com/forum/...threadid=18185

Finally tore the bike down tonite out of sheer curiousity and removed the whole harness. I'm just going to eat it and pay the $240 they want at the local Yamaha dealership for a new OEM harness. I'd feel better its new rather than finding another 10+ year old harness on ebay, and still end up paying $100+ for that anyways. Was just about how I summed up the job, had to remove all the body work, pull the airbox and gas tank and pretty much the whole harness was accessible. With an hour trip to town for errands, the whole thing probably took me 3.5 hours including cleanup this evening.

Heres some pics, since I know you guys like naked bikes.

The almost totally stripped Fizzer:



All my shit strewn everywhere:



Just a small taste of the damage. Nearly the entire harness had these 2 blue wires completely melted and burnt through to other wires. I honestly have no idea how the bike even still ran after cut all the loom and tape off and seeing the actual condition of it:



And heres what I think of the harness :

[FazerChic]

Holy shit Jeff!! It's about time you got that bike in good working condition.

At least it'll be good to go come the spring riding season!!! Just don't drop it again.

[JeffL]

I'm just gonna hit that scratched up spot on the fairing with some spray paint and call it good. I just noticed today that a small chunk broke off when it went down, so I'm not even gonna bother bondo/priming/repainting it. Spray paint is good 'nuff.

[breakdirt916]

Firstly, naked = sexy.

Secondly, isn't it a good feeling to know your bike inside out? You just stripped the bike down to pull out the entire main wiring harness.

[stoinkythepig]

Great work. Curious why the wires melted. Did you find the cause?

[ZX-12R]

Originally posted by stoinkythepig
Great work. Curious why the wires melted. Did you find the cause?

My thoughts exactly... What if the melted wire was only a symptom of something larger?

[bump909]

like aliens that bleed acid?

[richw]

I would look at schematic for what were

the blue wires doing.

Though if they are that roasted it probably is a
rub through to the frame.

If you gots the manual I'ld check the wire routing

[JeffL]

The blue wire is the power wire for the bikes lighting. It originally shorted out where it takes a really awkward bend out of the ignition cylinder/tumbler itself, and apparently took the rest of the wire with it.

[ZX-12R]

Make sure to protect that vulnerable area!