2010 990A electrical problem

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by FZcruzer, Mar 11, 2014.

  1. FZcruzer

    FZcruzer Been here awhile

    Joined:
    Apr 19, 2007
    Oddometer:
    710
    Location:
    Camarillo, Ca.
    Hello all,

    Went to start the bike, turned the key on, put the kill switch into the run position and nothing. No dash movement, nothing.

    Checked the battery voltage and it was at 2 volts:eek1. Thought maybe my cheap USB socket had drained the battery, and put the bike on the charger. As soon as I put the charger on I got the EFI light and heard the fuel pump start, this with the key off and the kill switch in the off psoition. Cycled the key and switch and it does not matter, with everything off the pump and dashboard trys to come to life

    Removed the battery and charged it, have not tested it yet to see if it is toast or not, took a full charge and will check the standing volatge after work today.

    I am thinking either I have a pinched wiring harness around the steering head like others have posted and have a short, or the ignition switch is bad.

    Anybody have any other ideas before tear into it? Can not really think of another common point where this would happen.

    Key off, even removed and the kill switch in the off postition and the bike is still powered.
    #1
  2. FZcruzer

    FZcruzer Been here awhile

    Joined:
    Apr 19, 2007
    Oddometer:
    710
    Location:
    Camarillo, Ca.
    Went out and checked wiring, found that if I wiggled the two wires that go into the bottom of the ignition switch I could cause it to short. Took the two screws out and removed the base of the switch and popped it apart.
    [​IMG]

    After removing the bottom of the switch I could see the insulation had pulled up on the wires and they could short.

    [​IMG]

    Added some shrink wrap to insulate the wires.

    [​IMG]

    Put it all back together and added some shrink wrap to add some protection.

    [​IMG]

    All back together and seems fine, hope this might help somebody else.
    #2
  3. Hootowl

    Hootowl Long timer

    Joined:
    Jul 2, 2002
    Oddometer:
    1,353
    Location:
    Bend Oregon
    Thanks for the pictorial
    #3
  4. ICERIDER

    ICERIDER Adventure Rider

    Joined:
    Jun 23, 2006
    Oddometer:
    855
    Location:
    Stanley Falkland Islands
    Thanks for the report. Nice solution you came up with. Might think of doing that to my 950's. It's strange there is no secondary anchor method for such an important wire. Yank on the wire and you are pulling at the solder.
    #4
  5. Dan Diego

    Dan Diego Long timer

    Joined:
    Dec 24, 2010
    Oddometer:
    1,436
    Location:
    San Diego, CA
    +1

    Much appreciated as this is likely a common issue.
    #5
  6. FZcruzer

    FZcruzer Been here awhile

    Joined:
    Apr 19, 2007
    Oddometer:
    710
    Location:
    Camarillo, Ca.
    One more thing, the two screws that need to be removed to take the bottom if the switch apart are normal Phillips screws. I was worried they might be security screws but no problems.
    [​IMG]
    #6
  7. two trackin fool

    two trackin fool Long timer

    Joined:
    Nov 6, 2010
    Oddometer:
    1,615
    Location:
    Mobile with any Luck if not Michigan
    [​IMG]

    [​IMG]

    [​IMG]

    Luckly mine started acting up when I was home in the garage doing a 6 point park job
    #7
  8. FZcruzer

    FZcruzer Been here awhile

    Joined:
    Apr 19, 2007
    Oddometer:
    710
    Location:
    Camarillo, Ca.
    Cool you figured it out. The damage to yours is a lot different than what mine looked like.
    #8
  9. two trackin fool

    two trackin fool Long timer

    Joined:
    Nov 6, 2010
    Oddometer:
    1,615
    Location:
    Mobile with any Luck if not Michigan
    Thanks for the heads up !

    I will tie my harness up better so I don't have the same issue as you !

    Wondering about the thread too . Would think they could come up with a better design ........
    #9
  10. gefr

    gefr Life is a trip

    Joined:
    Nov 26, 2005
    Oddometer:
    4,633
    Location:
    East Med, Greece
    In mine, the wires were tightly wrapped with a tie wrap around the switch barrel, as they come out. That bends them but keeps them still. The replacement I bought was exactly the same. Wires were tie wrapped on the switch barrel.
    Cheers
    #10