Melted wiring harness!

[terrylee]

Took wifes' 81 450 for maiden voyage to day (been redoing since last Sept. Bike was doing pretty well although some small issues. All of sudden everything on bike went dead and it had blown the main fuse (only one it has). Tried changing fuse and it blow too. Almost off the connections on this bike have been replaced along with new spade fuse holder. So dumba_ _ I am I bypassed fuse long enough to get home, which was only two miles. Well of course I now have a meted wiring harness, so bad there is no way I can cut and splice. Now that I've stopped crying, I thought I'd ask if anyone has one that might work on this bike? (Will post in want ads too). I do have a harness off a 78 550 that might work but wiring is different at one point because 78 had reg. and rectifier separate. Anyone have a wiring diagrahm for 78 550, looked on Basscliff but didn't see one. Does any one know where to get a new one that would work. Thanks so much terrylee.

 

[Nessism]

I suggest a wiring harness from a bike with electronic ignition - 1980+, since your 450 has same. I adapted a 1000G harness into a 1000S so anything is possible as long as you are willing to do some grafting work.

 

[BassCliff]

Hi,

On my site there's a GS550 service manual for '77-'82 models. There should be a wiring diagram in there for the '78.


Thank you for your indulgence,

BassCliff

 

[Guest]

Sorry Terry
I hope you find the short

 

[terrylee]

Thanks guys! I'm hoping a new harness will take care of the short if not I'll fiqure it out. Sorry Basscliff didn't see it! One of the guys has one from a 81 550, that should work right? terrylee

 

[Larry D]

How badly is it melted ? Is there any way to cut out the affected wires and replace them with some connectors of some sort ? Seems an easier way to go rather than replacing the entire wiring harness.

Of course you need to find the reason it melted and repair that first.

EDIT:: Nevermind.....I missed that sentence in your original post.

 

[terrylee]

Melted into a blob from top of airbox to triple tree, so nearly impossible to cut out, although I thought about it, but I just don't think it is to easily done. At least it is only the main harness all the sections which connect to it are not fried. terrylee

 

[GabrielGoes]

Melted into a blob from top of airbox to triple tree, so nearly impossible to cut out, although I thought about it, but I just don't think it is to easily done. At least it is only the main harness all the sections which connect to it are not fried. terrylee

i feel your pain 100% man. in my opinion just save it man, i know all about melted harness's lol i would really just save the harness i spent 12 hours all night saving mine, no waiting for shipments or anything, get'r done!

 

[terrylee]

One of the good guys on here has one off a 81 550T and it has a fuse box set up instead of just only one main fuse for the entire bike. So I would like to switch over to that. I pretty good with most elec. so I think I can handle it, anyone ever done this, if so any tips. If I have a wiring diagram for the 550 I think I can figure it out. terrylee

 

[terrylee]

ok, need some advice. Got the wiring harness for the 81 450 (bought one on ebay from 81 550T). Since it was set up for a fuse box I installed a new spade type and got all the wires hooked up according to diagram for the 550. Which looks to have come off a bike from Canada( at least according to diagram in service manual off of Basscliff site). Everything was exact match for what was left on 450. Everything works except the taillight, headlight and lights for speedo and tach.
The 450 even though it is a 81 has a on/off switch for lights, which always worked before I melted old wiring. All wires going to left handlebar switch are exact color and order match for where it plugs into main harness. It seems like the on/off switch is not turning anything on, I'm getting no juice to anything it controls. Did test the plug for ignition switch and getting juice coming into red wire of plug, but nothing when I touch the orange, brn, or gry. wires. with the key on and the ign. switch plugged into harness. But bike will start right up. I have double and tripled checked all connections which I either cleaned or replaced and can find nothing wrong. Help! My wife is dying to finally get to ride this project bike, which is ready to go except for this problem. terrylee

 

[GabrielGoes]

Everything works except the taillight, headlight and lights for speedo and tach.

The same exact problem for me as well.... If you followed the connection from the tailight headlight and speedo and see nothing is touching or melted and there all hot try to check the Left handlebar switch, open up the plastic compartment held by 2 screws on the bottom and take a good look. i gaurentee one of the soldering ends is off or is just really a bad connection... its the only reason i see all 3 not working simultaenously(sp?). Get inside the switch and just solder the connections on the switch again, if you have to bypass the switch and solder them all together so the headlight is always on... the test light always helps, test lights dont lie and sometimes the problem could lead to the key switch... the contacts could be dirty... i think 1 screw hold the key switch in place directly beneath the key area... its gotta be the switch on the left handlebar!ray:

 

[terrylee]

Thanks for response. Did recheck ign. switch plug and am getting juice at red and org. wires, but nothing to brn or gry. Haven't tried taking handlebar switch apart yet, but will try that tonight. Although I did have a old handlebar switch of same kind from parts bike, plugged it into harness and still got nothing. Will also check bottom of ign. key switch (I did have to change out wiring on it recently while doing all this project, because wires were fried to it) so maybe the switch is a problem. When you turn the key on the oil, and neutral light on dash do come on. terrylee

 

[GabrielGoes]

When you turn the key on the oil, and neutral light on dash do come on. terrylee

same thing happend to me! its gotta be a bad switch connection i mean for the dead wires i would just follow it all theway up to where its connected/soldered

 

[terrylee]

You were right the org. wire inside the handlebar switch was disconnectd. So soldered it back on and it worked! Then put all the wires back into headlight bucket and turned key on and the fuse to the lights blew. As long has I leave the switch to off the fuse is fine, the second I turn it on the fuse blows. Had spare switch so cleaned it up and put it on plugged it into main harness and does same thing. So know it is not the switch at least. Will be taking all the wires back out of headlight and checking all them for short or something. Didnt' start blowing fuses till after put back together so I figure it has to be something in there. terrylee

 

[terrylee]

help! going insane!

help! going insane!

I pulled the headlight and checked all connections and inspected all the wires for fraying and could find nothing. Tried hooking back old handlebar light switch and still blew fuses. If I put the bike in the "park" mode (so only tail light comes on)it comes right on and doesn't blow fuse. I unhooked all connections in bucket one at a time and made no difference. The only thing I can think to do is cut cover off headlight wires in the main harness and follow them as far as they go and look for a short. I went through 25 fuses! I even changed where the fuse for the lights on the fuse box plugs in to a different spot and still no change. I feel it has to be the headlight is the problem since tail light will come on and not blow the fuse, as long as headlight switch is on off. terrylee

 

[terrylee]

getting worse!

getting worse!

Went out to bike and lights came on and didn't blow fuse.
so hooked up headlight and left on a while, turned key off and on, switched between low and high. Thought maybe some of the contact spray I used to clean switch and wires might have not dried completely and now was. Grouped wires back together to put back in headlight bucket and blew fuse! Took all wires and spread them back out and again tried to find a short or bad wire, still see nothing! But now when you turn the headlight on it is not blowing the fuse to the lights, it's now blowing the main fuse. Also I noticed, although I have no idea if it is connected, but one of the coils is getting hot on the end of one of the posts if I leave the key on very long. Unplugged it for now, but made no difference in blowing fuses. terrylee

 

[GabrielGoes]

So soldered it back on and it worked! Then put all the wires back into headlight bucket and turned key on and the fuse to the lights blew.

first of all id just like to say i have gone through the SAME exact kind of situation + even more electrical disasters, look up some of my threads you'll see what i mean lol.

Now what exactly "worked"?? how and what did you test? what exactly did you see when you say it "worked"

after reading your posts it sounds like you have problems when you shove things back in the headlight housing.. Heres what i gotta say, Take a break from the bike and Think about it (each connection and etc.) Think about the problem and troubleshoot in your room or something, I think its VERY important to stay away from the bike for a while and just relax and THINK...

now when you see a connection is 1000000% good and clean, move on and look elsewhere!, also if you havent cut off the rubber or plastic layer that covers and holds your harness together, nows a good time to do so!, make sure you can see every wire and follow each one, this will save you a lot. The Test Light will be your weapon of choice, I think since you said the fuse doesnt blow as long as you leave the switch off, you should look at the 3 wires that come from your switch, make sure that when you soldered that the glob is NO WHERE near the other 2 connections.

Then since theres only 3 wires on the switch, Follow each one from start all the way to finish! if they branch off some how follow each one of those as well, You will solve your current problem by following each wire from start to finish, ONE of the switch Wires has a faulty connection or is making contact, sounds like a bad ground or a ground is touching a live wire and shorting out... Check Each wire that goes to the Switch because SURELY one of them is bad,

After your done doing that, try turning it on, BTW what amp fuse are you using? what used to work may not work anymore because of certain circumstance and changes, you may need a bigger fuse (this doesnt seem likely by the way u explain things) If the fuse blows and continues to Check every wire especially the ones that come from your coils (you say its getting hot? very bad) and follow each one of those, Make Sure Each Ground is fully Grounded,

The Test light should be with you at all times.. Remember When you see a connection is good MOVE ON, process of elimination, There are only so many wires on the bike remember that! i really hope you get out of this electrical mess soon, I know you will eventually but i hope you fix it the next time you go check it out. Seriously Slow and Steady + Process of elimination with the Test Light is how your bikes gonna work again

 

[terrylee]

Thanks for all the suggestions, I did what you said last night, got away from it. I can't work on it this morning till and get more fuses. I will take the switch apart again and also going to take ign. switch apart and have a look there. I checked the ground wires last night, but will take another look. Then if none of that works it time to take harness back off and rip it apart and as you said check every wire. terrylee

 

[terrylee]

Took ign. switch apart and cleaned it and replaced the old connection. Soon as I turned on the key after plugging back in it did not blow fuse and lights worked. Had already taken switch apart and couldn't see anything wrong but did clean with some contact cleaner. Was shutting key off and on a few times and shut off lights with switch and no problems. Then I noticed the blue(bright) light on dash flickered if I pushed on it a little. So tried plugging in headlight and it blew fuse instantly. Had old plug so replaced one on bike with that one. And also took switch apart again and cleaned connects on the inside of the on/off part of switch. Made no difference. I just won a new switch on ebay, as I want to at least make sure that's not the problem. Did want to ask how I hook it up since everything is the same except doesn't have off/on part. I pretty sure I can handle hooking up everything else, but what or how do I hook it up so it has power at all times when key is on? Thanks for all and any help. terrylee

 

[Matchless]

So tried plugging in headlight and it blew fuse instantly.

Have you had a look at the bulb or tried another? Does it blow the fuse when on High or Low beam?