07 DRZ 400sm *died* :(:(

[zetecy]

Evening,

I turned my ignition on, followed by starting the engine which started straight away. Then after 1 second of running the engine stoped and the digital dash display went out. turned the key on and off a few times and nothing, no display.

so i thought, hopefully its just a fuse.

Replaced the main fuse, (it was blown) and turned the ignition on.. left the ignition on for about 10 secs and then it went out.main fuse blown again.

I decided to put the ammeter across the fuse holder and turned the ignition on.. it went to 16A initially then rocketed up and went off the displays reading and the wires became hot, so i quickly turned the ignition off..

i really cant think wots going on. i had just come back from a ride and put my bike outside the house. then all this started.

ive removed all the panels,seat and headlight cover to look for any wires randomly hanging out of their connectors but i cant see anything.

Id really appreciate help/ideas, ive got no bike at the mo!!!

[DrSmith]

[Hutchysrs50]

only think i can think is theres a wire came loose, or possibly a hidden one melted somewhere and earthing on the frame.

Hope this helps.
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Gilera SC 125 - Current

[G]

Seems like you've got a short circuit 'somewhere', it's just going to need more fiddling about. With ignition off, use the resistance setting on a multimeter to check various points against neutral on the battery (or the frame), as stuff with power running through it shouldn't be 'earthed' as such.
Oh and as you found out - don't go replacing a fuse with a multimeter, they're not really designed for the job .

[spitfire123]

whats your ALT charging at?
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You won't be able to eat my dust......As it'll settle before you get there.

[zetecy]

right, after 7 hours of testing, ive given up and put everything back together.. however (sorry for the rhym)

new breakthrough!!... magically i can turn the ignition on without blowing anything. and i even started it and let it idle. but i happened to have caught my hand on the clutch cable and it was boiling hot! i mean extremely hot! i was like WTF. the only other cable that comes into contact with the clutch cable is the starter motor cable which was not hot. this is freaking me out. so i stopped the bike straight away and turned the iginition off. so does this mean i still have a short? i dont get how its now starting and not poping fuses. but the clutch cable is getting frieghteningly hot...

[zetecy]

[G]

It seems very likely the clutch cable is earthing the starter motor cable. Check where they are touching - maybe they have rubbed through the insulation of each other.

The starter motor cable is generally made of metal able to take a very high current, while the clutch cable is not really going to be designed to take any, though of course isn't the thinnest of wires.

[zetecy]

omfg!! G your right i think,

i just went to the garage and pulled the clutch lever its fucking seized!! i cant believe it! it must of heated so much and now coolled down and fucked it. excuse my swearing. shit. i still cant see where there touching

BRB going to check again now with a torch..

[zetecy]

right had a good look. the clutch cable does not interfere with the starter cable wire, there is contact but their both heavily insulated and not rubbed through..

So.. in my head, trying to narrow it down. . i have a clucth cable the gets really hot. so must it be up near the leaver? the clutch switch thing at the lever? has that got a live feed to it?

thanks guys

[TUG]

Suzuki's only start if you pull the clutch in dont they.....

I think you best look at the switch on the clutch perch? Hopefully your bike follows the suzuki trend and i'm not barking up the wrong tree.
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Haz ER-5, innit!

[zetecy]

yup, only start with clutch lever in.

yes im going to dismantle the lever and switch gear and after lots of swearing and mouthing off at the bike hopefully should see whats caused all this!

does anyone know if that clutch switch on the handle bar has a live 12V to it? cos im just trying to think how the hell does the clutch cable become HOT? it must have a voltage and then touching ground somewhere.

i hate electrical problems!

ill keep you posted!

[TUG]

The clutch switch will act as a push to open? switch so should have a feed in theory, if its not that then you will have to follow the cable to where ever it leads, electricity will travel to earth the quickest way possible with the least resistance.
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Haz ER-5, innit!

[G]

The 12v feed to the clutch lever will probably be by a very thin wire - I'd expect that to be pretty melted if it was making the actual clutch cable, which is made from chunkier stuff, to heat up.

[zetecy]

right guys, i found it. It was the a wire in the handle bar switch housing was touchting the handle bar which made the cable live (12v i tested it) and the 2 adjuster nuts where touching the little arm retainer thing where the clutch cable should sit, thus grounding the cable causing a short

pics to help explain my 12 hour ordeal diagnostics lol!

Thanks to everyone who helped. i would be stuck without you all.

see where the black insulator has melted..
https://i236.photobucket.com/albums/ff280/zetecy/18062009904.jpg

see the heat damage/contact to the handle bar
https://i236.photobucket.com/albums/ff280/zetecy/18062009905.jpg

and where its shorting that adjuster nut VS the retainer arm thing(grounding)
https://i236.photobucket.com/albums/ff280/zetecy/18062009906.jpg

here she is all working!
https://i236.photobucket.com/albums/ff280/zetecy/11062009897.jpg

thanks again

[TUG]

Your welcome lol. But you would of found it without us eventually, its impressive you didnt give up an fan it off good job mate.
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Haz ER-5, innit!