Where do the left grip eletric cables route on your 12?

[JPaddo]

Lost the headlights 4 times tonight on the freeway and on a couple of back roads... scary as! Seems to be vibration related. As soon as I hit the gas hard the bike goes dark.

I have a theory that these arseholes at Northern beaches routed my electrics from the left grip wrong.. I already had to replace the choke cable because of their f--- up

Can anyone have a quick look at their twelve and tell me does the cable with all the electric wiring in it from the left grip route outside or inside the radiator mounting point on the frame? (FYI mine is routed on the inside)

If anyone has any other ideas as to what could be causing it I'm open to suggestions.

[phear8me]

could you put up a pic of what exactly your on about?

[JPaddo]

could you put up a pic of what exactly your on about?

Hopefully this clears things up.

I'm talking about the cable labelled "9" from the left grip instruments.


This is a picture of the choke cable routing for comparison. (Note: the mechanics had the choke cable jammed between the radiator bracket and the frame, which caused the cable to snap). The electrical harness that contains the cables for the light switch and indicators is still jammed into that gap between the radiator bracket and the frame. I'm just wanting to know if this is where it is supposed to go, or it's yet another F--- up from the mechanic. (Note: they dropped the rad to do the exhaust so anything up around there from these jokers is suss imo)

[Wilso12r]

Water in the switch housing causes my lights to go out. Happened once in heavy rain and once after washing my bike.

Or, is it just your headlights or everything else on the switch housing, ie indicators and horn. Last service I had they failed to reconnect the wiring loom at all. When I took it back, they had to pull off the inner fairing (covering the air duct) to find both ends and reconnect. Just wondering if they failed to connect yours properly.

Just checked mine now and it is running on the inside of the fan mounting point but outside the radiator mounting point, if that makes any sense. Now I'm curious if that is where it should be as well??

[JPaddo]

Hmmm ok that's good news. I checked all the routing, cables and connectors. Seems fine. I've wiggled everything, steady beam no matter what. I guess it's either the relay issue or something with the globes. Come to think it did happen under acceleration (which is what led me to believe it was vibration related) so perhaps it's too much voltage getting to the lights causing them to overload or something and go out? (excuse my layman's)

[Jonno]

i will have a looksee at my stock 12R shortly.

[JPaddo]

Sounds like mine was done wrong. It's a tight squeeze in there too and I can't imagine it's good for the wiring. Given the rest of the work these guys did I pretty much expected it. I'll move it back where it should be pending Jonno's reply.

[Jonno]

The wiring from the left clip on switchblock goes around the front of the fork tube, across the top of the radiator plastic cover as seen in pic below and under the ram air tube on the left hand side, there should be a wiring wrap around clip and there is plenty of room around it, it isn't squeezed or anything it just lays across the top of the Radiator and should be clipped in with the choke cable and ign barrel wires x 2.

wiring1.jpg (137.18 KiB) Viewed 3862 times

What bulbs are installed?


Yes I removed that stone

[JPaddo]

Awesome Jonno thanks. Yep mine was definitely done wrong then! No clip to speak of... it may still be there though I need to have another look. Maybe they lost it and decided to jam it between the rad and frame instead.

Grrr.

Globes are phillips Halogens. 12V 60/55W. The cap is black.

Even though the wiring was done wrong my utter failure to induce the problem leads me to believe its maybe stator related / too much / too little voltage? I dunno much about this sort of stuff.

[Wilso12r]

So, thanks Paddo for bringing this topic up, I went and had a closer look and found this......

Plastic guard has been forced up and wire pushed up underneath (blue tape)

PB200053.JPG (55.87 KiB) Viewed 3840 times

wiring rubbing on fan. Bit hard to see but it is the wire with the blue insulation tape

PB200056.JPG (34.39 KiB) Viewed 3840 times

Wiring running under plastic guard instead of over. No clip to hold.

PB200062.JPG (44.88 KiB) Viewed 3840 times

The rubber must have been torn when the mechanic pushed the wiring up where it wasn't meant to go.

PB200060.JPG (48.44 KiB) Viewed 3840 times

After an hour of digging, finally get down to it.

PB200064.JPG (45.8 KiB) Viewed 3840 times

Just cut through the insulation

PB200065.JPG (41.28 KiB) Viewed 3840 times

So, mine was obviously wrong. In to the bargain, two of their mechanics couldn't get it right. The first one that forgot to reconnect it and the second one who connected while I was waiting to get home. So I'll be making a phone call in the morning. Not happy at all.

Thanks for the info Jonno. I don't appear to have the clip that holds all the wires on the left side either. Now I am wondering about the choke cable, which runs between the radiator mount and the frame, instead of outside the radiator mount (3rd picture). Also the radiator overflow line goes through just above my fans (1st picture). Not sure if both of these are right either???

[JPaddo]

Wow talk about can of worms! My choke cable was routed through there too... but it was so crowded with the other cables that it got squashed and caused the cable to break in that exact spot.

Have a mate who's an electrical engineer and after looking at the wiring diagram reckons it's either a dodgy connection, a problem with the fan (apparently on same circuit), or a faulty relay. Said it's highly unlikely it's anything with the globes, also reckons the switch housing wouldn't affect it.

Glad this thread was able to help Wilso.

[Jonno]

lets hope mine is correct, i reckon it is.

[Wilso12r]

I reckon it is too!!

[JPaddo]

Hmmm ok so I fixed the routing (bracket was still there), no obvious damage... Double checked all connectors, checked the fuses. ECU fuse had lots of corrosion I cleaned it up back to metal on metal. Swapped the headlight and tail-light fuse for good measure and buttoned it back up.

Pissing down atm but next time I get some clear weather I'll take her for a burl at night see if I can replicate the prob. I'll get some new bulbs just for good measure see how we go.

If it's still stuffed after all that then it has to be a dodgy relay I spose? Do the B models get the stator wick prob?
Anyway we'll see.

[Jonno]

wires may have been pinched/broken or it could be in the plug if they tugged it through to hard. dont think its globes, rectifier you could test with a multimeter, same across all connections like fuse blocks, battery charge etc looking for drops in voltage, check your earth from battery to frame too.

I would be looking at everything they may have disturbed doing the job they did. yes pull all the covers and check. they sound like a bunch of amateurs.