new breaks on front

DSN_KLR650
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Norm Keller
Posts: 712
Joined: Thu Apr 01, 2004 7:48 am

main wiring plug warning

Post by Norm Keller » Sat Sep 06, 2014 12:42 am

#ygrps-yiv-1902568466 blockquote.ygrps-yiv-1902568466cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-1902568466 blockquote.ygrps-yiv-1902568466cite2 {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;margin-top:3px;padding-top:0px;} #ygrps-yiv-1902568466 .ygrps-yiv-1902568466plain pre, #ygrps-yiv-1902568466 .ygrps-yiv-1902568466plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;} #ygrps-yiv-1902568466 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-1902568466 .ygrps-yiv-1902568466plain pre, #ygrps-yiv-1902568466 .ygrps-yiv-1902568466plain tt {font-family:Tahoma;font-size:12pt;} Out riding tonight and lost headlight, tail light, dash lights & signals.   Of course this was the one time in the last 10 years I didn't have a pocket flashlight and didn't want to shut off in case it was a Brown wire issue. Thinking about it, seemed like a red wire issue but didn't want to chance as had my LED running lights in front signals and hand guards. They were adequate light to see on country back roads so was a good test. Had brake light also so not concerned about being rear ended.   It did restart when got home although could have confirmed that by simply shutting off while the bike was at speed. No need to do work on road side with my running lights.   Pulled the plastic bucket over the main wiring plug and, as expected, the red wire circuit was interrupted because the second plug from the left was partially out. I had unplugged these when doing the pin out diagrams so thought I must not have completely seated the plug.   Turned out that the small latch which is supposed to lock the two plug bodies has lost tension and doesn't hold reliably. 1987 so not unexpected that plastic is weakening.   I now have a new standard procedure for Gen1: I will run tie wraps (zip ties) between the wires on each side of the plug and tighten the tie around the plugs and the mounting bracket to prevent the plugs from coming apart.   The plug shook apart when I pulled into some gravel to U turn so it was the shaking/bumps.   Others may wish to consider whether this is worthy of attention.   https://www.dropbox.com/s/at7p628oojxgqhz/Tie%20wrap%20main%20wiring%20plugs.jpg?dl=0   https://www.dropbox.com/s/9pyy03qrha40u2w/Tie%20wrap%20main%20wiring%20plugs2.jpg?dl=0

Buddy Eckles
Posts: 51
Joined: Thu Mar 04, 2010 7:55 pm

main wiring plug warning

Post by Buddy Eckles » Sat Sep 06, 2014 1:50 pm

#ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass blockquote.ygrps-yiv-1687900100ecxcite { padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass blockquote.ygrps-yiv-1687900100ecxcite2 { padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;padding-top:0px;} #ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass .ygrps-yiv-1687900100ecxplain pre, #ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass .ygrps-yiv-1687900100ecxplain tt { font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;} #ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass body { font-family:Tahoma;font-size:12pt;} #ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass .ygrps-yiv-1687900100ecxplain pre, #ygrps-yiv-1687900100 .ygrps-yiv-1687900100ExternalClass .ygrps-yiv-1687900100ecxplain tt { font-family:Tahoma;font-size:12pt;} Out riding tonight and lost headlight, tail light, dash lights & signals.   Of course this was the one time in the last 10 years I didn't have a pocket flashlight and didn't want to shut off in case it was a Brown wire issue. Thinking about it, seemed like a red wire issue but didn't want to chance as had my LED running lights in front signals and hand guards. They were adequate light to see on country back roads so was a good test. Had brake light also so not concerned about being rear ended.   It did restart when got home although could have confirmed that by simply shutting off while the bike was at speed. No need to do work on road side with my running lights.   Pulled the plastic bucket over the main wiring plug and, as expected, the red wire circuit was interrupted because the second plug from the left was partially out. I had unplugged these when doing the pin out diagrams so thought I must not have completely seated the plug.   Turned out that the small latch which is supposed to lock the two plug bodies has lost tension and doesn't hold reliably. 1987 so not unexpected that plastic is weakening.   I now have a new standard procedure for Gen1: I will run tie wraps (zip ties) between the wires on each side of the plug and tighten the tie around the plugs and the mounting bracket to prevent the plugs from coming apart.   The plug shook apart when I pulled into some gravel to U turn so it was the shaking/bumps.   Others may wish to consider whether this is worthy of attention.   https://www.dropbox.com/s/at7p628oojxgqhz/Tie%20wrap%20main%20wiring%20plugs.jpg?dl=0   https://www.dropbox.com/s/9pyy03qrha40u2w/Tie%20wrap%20main%20wiring%20plugs2.jpg?dl=0

Norm Keller
Posts: 712
Joined: Thu Apr 01, 2004 7:48 am

new breaks on front

Post by Norm Keller » Sat Sep 06, 2014 2:46 pm

#ygrps-yiv-2084690452 blockquote.ygrps-yiv-2084690452cite {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;} #ygrps-yiv-2084690452 blockquote.ygrps-yiv-2084690452cite2 {margin-left:5px;margin-right:0px;padding-left:10px;padding-right:0px;border-left:1px solid #cccccc;margin-top:3px;padding-top:0px;} #ygrps-yiv-2084690452 .ygrps-yiv-2084690452plain pre, #ygrps-yiv-2084690452 .ygrps-yiv-2084690452plain tt {font-family:monospace;font-size:100%;font-weight:normal;font-style:normal;} #ygrps-yiv-2084690452 {font-family:Tahoma;font-size:12pt;} #ygrps-yiv-2084690452 .ygrps-yiv-2084690452plain pre, #ygrps-yiv-2084690452 .ygrps-yiv-2084690452plain tt {font-family:Tahoma;font-size:12pt;} Robert, as you will know the impressions and discussions regarding the front brakes in particular go all the way from excellent to none.  ;-)   Part of it is of course subjective while for someone who weighs twice what I do, carries a passenger & camping gear will have objectively poorer brakes.   Glad to hear that the pad upgrade was satisfactory for your purpose. I will add that to my mental data base.   I like the steel braid reinforced brake hoses because they decrease the hose ballooning and so retain more lever travel.

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