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Old 10-11-2007, 09:03 AM   #1
Metzzen1
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Why are my connectors shorting out?

Been real busy lately, not much time to ride my bike. But last week i went and started up the bike and rode it around (durin the day) and later that day i was riding home (now night) and i noticed that my headlights were flickering really bad on and off and so were my guages. Well long story short (no pun intended), the 12V wire that goes through the main wire harness connector (near radiator, big white plastic covered plug) is corroded/rusted and was not making good contact. Had to splice a wire from one side of the connector to the other bypassing the plug altogether.

This has happened on both of the last two engine/wire harnesses i have had and im wondering what Im doing wrong here.

The first thing that comes to mind is rain, well yea i do get caught in the rain sometimes considering 90% of my commuting/traveling is on my bike. BUT i keep Di-electric grease in the connectors, and the entire connector was covered in electrical tape making it as water tight as possible. I also get home and wipe the entire bike down, and then put a big fan in front of the bike to dry everything out overnight.

Now one thing in common between the two wire harnesses is the headlights. I use the silverstar headlight bulbs. Could that be my problem?

I'ce checked all my other connections, all tight, no bare wires anywhere, everything is insulated properly.


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Old 10-11-2007, 11:47 AM   #2
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are the wires you are using the same guage?

maybe you have a minor leak somewhere/morning dew that is running down the harness and settling on that spot?
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Old 10-11-2007, 12:27 PM   #3
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are which wires the same guage?

When this happened the entire wire harness was 100% stock. Only reason it is modified now is because of the splice described above. the splice was done in 10g where the stock 12V wire is 14g i think, or 12g, either way its smaller.
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Old 10-11-2007, 12:47 PM   #4
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Originally Posted by Metzzen1 View Post
are which wires the same guage?

When this happened the entire wire harness was 100% stock. Only reason it is modified now is because of the splice described above. the splice was done in 10g where the stock 12V wire is 14g i think, or 12g, either way its smaller.
sorry, i meant the wire you used to jump it with. if its corrosion then maintaining it better would seem as the best answer.

you think you can open up that harness and replace that entire wire or section with a similar size?
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Old 10-11-2007, 12:55 PM   #5
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Battery connections normally vibrates loose and by having loose connection create heats and that speeds up the corrosion. Loose battery terminal can also caused heat in wiring and meltdown of insulation and then shorted. Be sure to check your fairing and battery bolts or any bolts on your bike periodically.
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Old 10-11-2007, 07:50 PM   #6
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^^^^^ Yup.... If its not direct water ingress throught the top of the wires(hot glue will stop it, but shouldn't be necessary; and comes off easily) then we usually see problems with poor ground straps. If aluminum frame, check the ground wires to the block(not sure off hand where they'd be...
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