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C650GT Intermittent no crank and no brake light.

steve l

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Joined
Feb 12, 2017
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68
Location
York UK
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C650GT Intermittent no crank and no brake light.

On a few occasions this year I have been unable to get the bike to crank and therefore start. The second time this happened I noticed the rear brake light not working and was able to start the engine by operating the front brake. I judged the most likely cause to be a faulty stop lamp switch and fitted a new one (at an outrageous cost of 50 UK Pounds) but it did not resolve the issue.

Studying the wiring diagram (see photos) showed the unusual feature of splice joints in the middle of the harness. Investigations revealed these joints to be at the point where the wiring flexes to accommodate the steering and a broken wire was found. See photos. The rigid sleeves fitted at a point where the harness continually moves means this is a likely point of failure on all our bikes.
 

Attachments

  • Broken Wire Diagram.webp
    Broken Wire Diagram.webp
    64.3 KB · Views: 9
  • Broken Wire Overview.webp
    Broken Wire Overview.webp
    384.4 KB · Views: 9
  • Broken Wire Close.webp
    Broken Wire Close.webp
    265.4 KB · Views: 9
  • Broken Wire Splice.webp
    Broken Wire Splice.webp
    98.6 KB · Views: 9
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