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Author Topic: Elecktricky stuff  (Read 8311 times)

Offline JPaganel

  • ^ Proficient Motobricker
  • Posts: 184
Elecktricky stuff
« on: September 20, 2018, 11:23:12 PM »
So, the clutch on my R got wonky. That is neither a small nor a cheap repair, so I turned my attention to the K languishing in the garage.

It has bad electrics. Fuel pump wires shocked me, but only when I managed to actually turn on the ignition.

The ignition switch is apart and soaking in degreaser. It was full of what looks like normal axle grease that hardened like cosmoline.  Someone has been in it and one of the clips holding it to the rubber pad is busted, but I think it will be fine.

When I looked at the pump wires, I realized that they had broken insulation, but the wires were actually whole. So, I got my handy-dandy Weatherpak connector tool, popped the pins, and put heatshrink wherever there was bare wire sticking out.  Result is in the attached picture. Hopefully, that will keep 'er from farting in church.

Also, I was pleasantly surprised that the headlight cover I have is ABS. I know how to work that stuff pretty well. I glued the cracks and duct taped it, it's drying.


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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline natalena

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Re: Elecktricky stuff
« Reply #1 on: September 21, 2018, 07:26:11 AM »
That's some nice clean work for such short fiddly wires,  "dohn 'cha know".
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  • MST
  • 1987 K75s #0919, '05 Sportster 1200C, '21 ARGO 8x8, '24 KLR650
"Hard to beat a 10x beaver, 'specially if you're gonna work it."

Offline JPaganel

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Re: Elecktricky stuff
« Reply #2 on: September 22, 2018, 04:55:11 PM »
Quote from: natalena on September 21, 2018, 07:26:11 AM
That's some nice clean work for such short fiddly wires,  "dohn 'cha know".

Being able to cleanly disassemble and reassemble the connector makes a lot of  difference.  That tool is worth it's weight in gold.
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline JPaganel

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Re: Elecktricky stuff
« Reply #3 on: September 22, 2018, 10:12:29 PM »
So... Battery is toast.

Getting it out was... uncomfortable. Bolts are corroded.  At least,  there was enough room for vise-grips. 

Ordered some stainless Allen bolts to replace them.  M6x80, not that common of a size.
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline JPaganel

  • ^ Proficient Motobricker
  • Posts: 184
Re: Elecktricky stuff
« Reply #4 on: October 01, 2018, 02:00:07 AM »
More electrical fun - brake light warning came on, and rear brake doesn't turn on the signal.

One of the wires broke off the little black connector in the picture.

Not sure what I'm gonna do about that yet...
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline CNRED

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  • Posts: 149
Re: Elecktricky stuff
« Reply #5 on: October 01, 2018, 08:14:54 AM »
Quote from: JPaganel on September 22, 2018, 04:55:11 PM
Being able to cleanly disassemble and reassemble the connector makes a lot of  difference.  That tool is worth it's weight in gold.

Lets see a pic of the tool or where it can be obtained....
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  • Scottsdale, AZ
  • 1990 K75rt, 1992GSPD

Offline johnny

  • TrailBrakingThrottleWhacker
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  • Posts: 7652
  • Whacking...n...Chopping Sliding...n...High Siding
Re: Elecktricky stuff
« Reply #6 on: October 01, 2018, 09:40:58 AM »
greetings...

i dont know what he is using... butts this kit is a must have for discerning brickers...


* 818vIJ8VSUL._SY879_.jpg (56.14 kB . 441x576 - viewed 455 times)

j o
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  • :johnny i parks my 96 eleven hundert rs motobrick in dodge county cheezconsin  :johnny

Offline JPaganel

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Re: Elecktricky stuff
« Reply #7 on: October 01, 2018, 11:28:47 AM »
Quote from: CNRED on October 01, 2018, 08:14:54 AM
Lets see a pic of the tool or where it can be obtained....

The tool is the yellow screwdriver-looking thing in the lower right hand corner of Johnny's picture.

You can get them a few different places, I like these guys: https://www.corsa-technic.com/category.php?category_id=88

They are across the river from me, in Johnny's neck of the woods.
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline rbm

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Re: Elecktricky stuff
« Reply #8 on: October 01, 2018, 08:53:18 PM »
Quote from: CNRED on October 01, 2018, 08:14:54 AM
Lets see a pic of the tool or where it can be obtained....
It's an AMP circular connector extractor.  Available from Digikey, Mouser, and other online electronics supply outlets.
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  • Regards, Robert
Toronto, Ontario

1987 K75 - Build Blog @http://k75retro.blogspot.ca/

Offline JPaganel

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  • Posts: 184
Re: Elecktricky stuff
« Reply #9 on: October 04, 2018, 01:16:04 AM »
Fixeded the rear brake connector. Pulled the pin and soldered the wire to it.

Electrical funsies continue:

* Looks like I have a fried bulb in the lower left corner of the cluster. 
* Blinkers are s=l=o=o=w.
* GPI is toast. Shows nothing but some murk.  Neutral light works fine, so I think it's just the LCD or the board that's gone.


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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline JPaganel

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Re: Elecktricky stuff
« Reply #10 on: October 06, 2018, 04:56:03 PM »
This is what the gear indicator looks like.

I think it's safe to say LCD is shot.

I take it the only fix is a good used board?
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline Laitch

  • Faster than a speeding pullet
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Re: Elecktricky stuff
« Reply #11 on: October 06, 2018, 05:06:59 PM »
Quote from: JPaganel on October 06, 2018, 04:56:03 PM
I take it the only fix is a good used board?
That's not the only fix. This thread has ideas and there might even be some production going on out there somewhere.
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  • Along the Ridley in Vermont.
  • 1995 K75 89,000 miles

Offline JPaganel

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Re: Elecktricky stuff
« Reply #12 on: October 06, 2018, 05:09:42 PM »
Quote from: Laitch on October 06, 2018, 05:06:59 PM
That's not the only fix. This thread has ideas and there might even be some production going on out there somewhere.

Nifty. 

It's not really all THAT important, but would be cool to have it working.
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline CNRED

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Re: Elecktricky stuff
« Reply #13 on: October 06, 2018, 06:15:49 PM »
Have you checked the Transmission Gear Position switch?
The procedure to check it is not all that difficult.  The switch 4 pin connctor is located on the right side of the bike.
The procedure is listed on this site, look for: Transmission Gear Position Switch Troubleshooting ~ author brian curry.pdf
I had the same proble, no Neutral light, no Gear Position indication.  Bike would only start withn the clutch pulled in.  Checked the switch found it to be faulty.  Gonna replace it with a TGPS from a parts bike that checks OK.
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  • Scottsdale, AZ
  • 1990 K75rt, 1992GSPD

Offline rbm

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Re: Elecktricky stuff
« Reply #14 on: October 06, 2018, 06:37:18 PM »
Quote from: Laitch on October 06, 2018, 05:06:59 PM
That's not the only fix. This thread has ideas and there might even be some production going on out there somewhere.
I've prototyped a LED replacement for the LCD on the gear indicator.   My impediment to moving forward right now is prototyping the mounting hardware but I don't have access to a 3D printer to try out designs.  If you'd like to experiment with this LED replacement board, I can build you one for a reasonable cost.

Try CNRED's advice first.  If the switch is faulty, the display will try to indicate "7" and that results in a blank display.  One test is to disconnect the TGPI switch at its connector just under the right battery cover.  Then take a piece of wire and short Brown to any of the Yellow wires on the harness side of the connector.  If the display is good, it will indicate a "1", "2" or "4" when you run this test.
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  • Regards, Robert
Toronto, Ontario

1987 K75 - Build Blog @http://k75retro.blogspot.ca/

Offline JPaganel

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Re: Elecktricky stuff
« Reply #15 on: October 06, 2018, 08:43:17 PM »
Quote from: CNRED link=topic=11726.msg102924#msg102924 date=153886414t9
Have you checked the Transmission Gear Position switch?
The procedure to check it is not all that difficult.  The switch 4 pin connctor is located on the right side of the bike.
The procedure is listed on this site, look for: Transmission Gear Position Switch Troubleshooting ~ author brian curry.pdf
I had the same proble, no Neutral light, no Gear Position indication.  Bike would only start withn the clutch pulled in.  Checked the switch found it to be faulty.  Gonna replace it with a TGPS from a parts bike that checks OK.

I haven't checked the switch. However, I have no issues with starting with clutch let out, and the neutral light works perfectly.

Quote from: rbm on October 06, 2018, 06:37:18 PM
I've prototyped a LED replacement for the LCD on the gear indicator.   My impediment to moving forward right now is prototyping the mounting hardware but I don't have access to a 3D printer to try out designs.  If you'd like to experiment with this LED replacement board, I can build you one for a reasonable cost.
Thanks. I will give that a think.
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS

Offline rbm

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Re: Elecktricky stuff
« Reply #16 on: October 06, 2018, 08:47:35 PM »
Quote from: JPaganel on October 06, 2018, 08:43:17 PM
I haven't checked the switch. However, I have no issues with starting with clutch let out, and the neutral light works perfectly.
Ok, it's the LCD display then.  If the neutral light works perfectly, then the TGPI switch is also fully operational as is the TGPI board in the OEM cluster.
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  • Regards, Robert
Toronto, Ontario

1987 K75 - Build Blog @http://k75retro.blogspot.ca/

Offline JPaganel

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Re: Elecktricky stuff
« Reply #17 on: October 06, 2018, 10:06:42 PM »
Quote from: rbm on October 06, 2018, 08:47:35 PM
Ok, it's the LCD display then.  If the neutral light works perfectly, then the TGPI switch is also fully operational as is the TGPI board in the OEM cluster.
Yeah, I am pretty sure the crystal leaked. It has the characteristic "floaters".
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  • Minnesnowta
  • 1986 K100RT, 1996 R1100RS
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