bike just fried itself

[bigbike-r]

was riding through town today - it had been raining heavy earlier and the bike cut on to 2 cylinders - so i had a look under the tank but couldnt see anything wrong power to everything so just put it down to rain - then when i went back out i was riding about 20 mins when i stopped at the lights and there was smoke coming up through the fairings - i thought it was steam off the pipes till i smelled it - pulled over and the loom is fryed - started splitting it open and it seems to be the ignition wires that have overloaded and melted there way open
the fuse didnt trip to protect the circiuit either

what could have caused it?


p.s 1991 gsx600f is the bike

[katanawarrior]

A short before the fuse? Improper or Ill-maintained connectors (No Die electric grease sp?) Insulation rubbed through? Fuses help but never count on them

[bigbike-r]

i made a temporary repair using some insulation tape wrapped them all up well made sure theres no where for wire to contact with anything - put some tin foil under the wiring on the head to act as a heat shield went or a ride - checked it all - everything good
went out again with the lights on - i suspected the lights be the problem at first hand as it was the brown wire that mainly fried - come back and the loom has started frying again - all the lights work but must be making contact somehow? whats the deal with it

[bigbike-r]

i think in the morning its gonna be worthwhile me ripping out the ignition wires and replacing them and trying that - before i resort to a new loom

[Trackerrrr]

You can find used looms on ebay quite a bit as an alternative, or check with Arsenic, he may have a used one for sale.

[bigbike-r]

yeah - theres a couple on ebay now for £20 wich isnt a bad price really - theres one brand new for £60 trouble is im absolutely skint lol

[itfben]

my loom has melted, but dont know why? like badly melt ont he main loom that runs down the o/s (left) of the bike.

anyone got any ideas?

will replacing the loom do it? or will a component fry it again?

[Smokey]

my loom has melted, but dont know why? like badly melt ont he main loom that runs down the o/s (left) of the bike.

anyone got any ideas?

will replacing the loom do it? or will a component fry it again?

Unless you can find somewhere that the loom has obviously rubbed through the insulation, you need to check out each circuit before putting power to a new loom. The wires melting the insulation is just a symptom, the real cause is a short somewhere.

[itfben]

bumb question coming up... how do I check each circuit?

oh and thanks for the help, appreciated!

[Kreylyn]

Improper or dirty connections (smaller area of contact for the flow of electrons) produces heat.... This means normal amount of energy traveling so as not to trip the fuses, but lots of heat build up.

Check the connections.

Krey

[itfben]

Improper or dirty connections (smaller area of contact for the flow of electrons) produces heat.... This means normal amount of energy traveling so as not to trip the fuses, but lots of heat build up.

Check the connections.

Krey

how / can this be fixed?

[Kreylyn]

how / can this be fixed?

Pull each connection, clean/remove any buildup of corrosion, apply dielectric grease to prevent water/buildup in the future.

Basically... if it looks dirty/rusty/corroded... it will not give you a good connection. Chemical or abrasives (like sand paper or steel wool) can be used to clean them.

Also keep in mind that bends in the wire, or pressure (crimped wires, clamped wires, wires trapped between parts) will do the same.

Also check all grounds to make sure they are clean and have a good surface area contact.

krey

[DumbLuck]

bumb question coming up... how do I check each circuit?

oh and thanks for the help, appreciated!

with the wiring diagram from your service manual and a multi-meter

[itfben]

with the wiring diagram from your service manual and a multi-meter

possibley a dumb question, but by service manual do you mean something like a Haynes Maunal as I have one of those, or do you mean something else?

[docbarlow]

Check the Pinch point under the front edge of the Clutch lever - I have seen Issues there, and the hi-Low switch is on that side, if the sleeve has slipped or the harness is not in it's little groove there could be problems

Doc