Large Tank Users - Check Your Wiring - Ducati.ms

lwood · Jul 30th, 2009, 2:56 pm

In a recent message I indicated that my Hyper died while riding - no electrical power, wouldn't start.

Dealer sent me a new battery - it also did not work. We traced down the main fuze in the rear (good shape) and the wires leading to the fuzes located up front. The front fuzes had popped.

What appeared to be the problem was the metal brace that goes over the middle of the expanded gas tank - in the middle of the bike. It has two rubber bumpers on it to support the seat.

Long story short, my support bar wore through the wrapping around the wires, (pictures attached) and the covering on several of the wires, exposing the bare wires and shorting them. The fuzes did what they were designed to do and popped.

Replaced the battery, the fuzes and double-wrapped the wires. Then ground away some of the metal support bar where it contacts the wiring - giving the wiring more room. Even if the seat bounces around - they should be safe.

Bottom line, if you have the big tank, check your wires and carry spare fuzes if possible.

Lee

mooner · Jul 30th, 2009, 3:01 pm

Thanks for the heads up, will check my wiring.

Caidly · Jul 30th, 2009, 3:23 pm

Tanks a lot!

bromike666 · Jul 30th, 2009, 5:45 pm

Exactly why I had Eric at PI do mine

typhon · Jul 30th, 2009, 6:41 pm

Quote:

Originally Posted by lwood

What appeared to be the problem was the metal brace that goes over the middle of the expanded gas tank - in the middle of the bike. It has two rubber bumpers on it to support the seat.

Then ground away some of the metal support bar where it contacts the wiring - giving the wiring more room.

Lee

just one (ok two) quick questions: what stresses do you think are applied to the metal brace and now that it has been compromised, what do you think the consequences of the broken brace would be

Endoz · Jul 30th, 2009, 6:51 pm

I ended up rounding off the corners of the metal brace, no edges now, (it was really jagged and sharp before)and extra heatshrink over the wires where they pass under it. Its now kinda a tight fit so i'll keep an eye on them, i may remove some extra material as well...

Endoz · Jul 30th, 2009, 6:54 pm

Quote:

Originally Posted by typhon

just one (ok two) quick questions: what stresses do you think are applied to the metal brace and now that it has been compromised, what do you think the consequences of the broken brace would be

I thought about this as well, but there's only four small allen heads holding that entire brace on, hard to believe its too heavily stressed, maybe just to help support the seat and keep it off the tank?

AirCaptain · Jul 30th, 2009, 7:37 pm

Nice heads ups. Thanks!

Dr. John · Jul 30th, 2009, 9:05 pm

Hey it's not just the big tanks folks. I wrote about this a year ago.

When my bike was back from it's 600 mile service I was looking it over to make sure everything was put back right I noticed that the plastic edging on that bracket was not on strait and it had rubbed through the tape around the wire harness.

I straitened out the plastic and wrapped the wires back up. No problems for a year and 11,000 miles, but I always check it when the seat is off.

Now we know happens when one of those wires grounds out on the bracket-total failure.

A word to the wise-

hbliam · Jul 30th, 2009, 9:13 pm

Routing hasn't changed on the larger tanks. You need to make sure your harness is properly routed regardless of which tank you are running.