98 EV Electrical Problems

[John A]

so what does that wire look like inside the connector? can you clamp the connector so it doesn't move and wiggle just the wire? of course trying to pinpoint the actual fail spot. sanity is only relative........... ...

[screamday]

That's actually a good idea. Don't know if I have enough room for even a smallish clamp.

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[guzzisteve]

I used slices of foam from pipe insulation between wires then wrapped w/elec tape to stabilize wire movement then wire ties to gusset on frame.

[Muley]

The '98 EV, one of the most popular Guzzis ever I'd wager, and one of the most aggravating too.

I can't help much on this one Tony, but I'm waiting for the outcome, which seems to be imminent.

Don't feel like the Lone Ranger though; I had a intermittent (and serious) problem for years on my '98. Once sorted out, it has been ultra reliable, only requiring normal maintenance, occasional bows to Guzzi quirkiness and minor repairs.

I'm sure yours will be fixed soon, and you can ride with confidence.

 

[John A]

Previously you showed a pic of the "A" connector and said it was the trouble, then showed the "B" connector and said it was the problem so it needs to be isolated . I'll give you a hunnerd bones for the bike, if you deliver it best to get offers in now

[screamday]

Previously you showed a pic of the "A" connector and said it was the trouble, then showed the "B" connector and said it was the problem so it needs to be isolated . I'll give you a hunnerd bones for the bike, if you deliver it best to get offers in now

Going back in tonight (time is my enemy) with the help of a friend. Hopefully a fresh pair of eyes and and uncluttered brain will help. I was bouncing back and forth between connectors because they are tied so closely together I couldn't tell which was the problem. Then I happened upon the green wire in "B" which seemed to give a consistent fault when I moved it. I'm gonna try to clamp the connectors down and just wiggle the wires to see where I stand. As far as selling the bike......if I could deliver it, that might mean that I found the problem and the price would go up.....exponentiall y. 

[John A]

sounds like a plan, hopefully it doesn't quit failing before you discover the real culprit. I wonder if that green wire powers other stuff thru the ignition switch or if the green wire powers the fuse thru the ignition switch.

[rodekyll]

I'll give you double, and you won't have to deliver it anywhere on account of I'll fix it on the spot and ride it home.

[John A]

that's boastful talk for a old hippie

[rodekyll]

 . ..an old hippie with a test light and a crimping pliars.      . . .and to make it interesting, I'll leave one or the other at home.   

[Kiwi_Roy]

Let's make it a challenge David - you only have 25 minutes to get it done LOL


Sent from my shoe phone!

[John A]

lets get likkered up so we can give him "helpful technical advice"

[Kiwi_Roy]

lets get likkered up so we can give him "helpful technical advice"

You must have been at the tent raising party - Deep Woods 2 years ago

[rodekyll]

30 minutes or it's free?  Sure.  I might not have it fixed in 30min, but I can point to the offender in that amount of time.  I just get to pick a day when my hands are working well enough to manage wires.

John, I like how you think.  You may attend the proceedings to hold my beer.   

You must have been at the tent raising party. Deep Woods 2 years ago.

Yeah, at Deep Forest we needed far more beer holders and far less technical advice.   

[screamday]

So......how much beer do I need  put on ice and how much duct tape do I need?

[rodekyll]

I'm a lightweight, so a couple of cases ought to do me.  That John though . . .    I saw him get through an entire soda in one sitting.  And don't get me started on his out-of-control coffee habit!  He has a tall one for BREAKFAST!  And Roy -- he's from BC.  Need I say more?

[John A]

I'm starting to fear for the safety of the EV. 

[screamday]

OK.....with a little help from a friend (he works part time at my favorite BMW Airhead shop) we feel pretty confident the connection at the green wire is suspect. I got the female connector out of the case and the connection between the wire and the connector looks sound. I have not yet got the male connector out of the case as it looks like it's forced in much deeper than the female. We have come to the conclusion that the physical connection between the two metal connectors is not tight and that is why we could recreate the fault by wiggling the wire. We tried putting a slight twist on the male connector but that didn't help. So, unless I can get the male connector out I will just by-pass the connector all together.

Here's what I have.

[Strom]

Sorry, did not notice the thread before....

You are on the right track...

Follow those cables from A and B (and right handlebar switch) to the steering head. The cables are usually under the chrome covers and flex where the chrome covers end.

I bet you a beer (if we ever meet) you have a broken cable at that point, from the lock or kill switch (depending on what dies) or one of the grounds.

Second thing would be the lock itself. Either only the turn signals and rear light dies or everything. Unscrew the bottom part of the lock, spray as much contact spray in the lock as you can, use an electric screwdriver with a flat head to turn the lock around a gazillion times, blow out stuff with compressed air, reassemble, do it annually... :)

Do not ask how I know....

[screamday]

Slow progress. Last night I was able to get both pins out of the connector. Then I ran a wire between the pins, bypassing the connector. On the surface it seemed to work. Might just be me hoping this is nearing the end. I'm going to try to figure out a way to better secure this connection then ride it for a couple of days (if it last that long) and see what happens. If this is truly the fix then I'll have to figure out what the next step will be. Maybe I'll just wait for guzzisteve to get his box of connectors and crimp then pay him a visit.

[Tom]

If everything lights up when you turn the key then you fixed it.

[mauricedonini]

Hi,

Any update?

Inquiring minds want to know.

Thank you.

[screamday]

Hi,

Any update?

Inquiring minds want to know.

Thank you.

Hey maurice, that last pic is the last thing I've done. Went out of town this past weekend and winter settled in for an encore here in SC before letting spring take the stage. I'm planning on loosely slapping everything back together and riding it for a couple of days to see how it works. Probably towards the end of the week (have to get some heat going in my garage). If I'm satisfied that it's working correctly, then I'll figure put a more permanent fix.

[Bucky]

 

[mauricedonini]

Hey maurice, that last pic is the last thing I've done. Went out of town this past weekend and winter settled in for an encore here in SC before letting spring take the stage. I'm planning on loosely slapping everything back together and riding it for a couple of days to see how it works. Probably towards the end of the week (have to get some heat going in my garage). If I'm satisfied that it's working correctly, then I'll figure put a more permanent fix.

Hi Tony,

Thanks for the update.

My curiosity is selfish.  I've a 99 EV.  Keep reading about electrical gremlins on these bikes.  Sounds like it's more a matter of when and not if.

Glad to read that you're real close to marking this issue as fixed.

 

[Kiwi_Roy]

I ran into a similar problem with my Lario a few weeks ago, riding along and it just died, then came back on a short while later. Turned out to be a couple of Molex connectors in the loom under the tank, Both the red wire up to the ignition switch and the Brown wire from switch to fuse block were overheating.
I went to all the trouble of getting replacement pins but in the end just crimped the wires around the connector, why set myself up for a future failure, a crimp will last forever.

[screamday]

I ran into a similar problem with my Lario, riding along and it just died, then came back on a short while later. Turned out to be a couple of Molex connectors in the loom under the tank, Both the red wire up to the ignition switch and the Brown wire from switch to fuse block were overheating.
I went to all the trouble of getting replacement pins but in the end just crimped the wires around the connector, why set myself up for a future failure, a crimp will last forever.

Yep. http://wildguzzi.com/forum/index.php?topic=89960.0