We pride ourselves on top maintenance of our fleet of '08 DL650's non-ABS, but even then stuff happens.
On our last tour, one of our bikes acted up for a guest. He reported "power cuts off between idle and 5000rpm." He is a master mechanic at Delta who maintains his Versys 1000, so I paid attention. I got on the bike and tried to replicate the problem. I thrashed it for a mile + and nothing. But just when I turned around it started cutting out, but not like fuel starvation, but electrical. Then it got bad and I didn't think I'd make it back but did. Even at speed it'd just shut off. I'd hit the starter, it may come back on, then a few seconds later just stop. I did make it back and we swapped bikes off the trailer (we always trailer a spare bike or two.
He has once complained about it didn't have much power, but I figured that was in comparison to his liter Versys.
Yesterday my tech and I got into the bike. I wanted to check the fuel filter so we drained the tank. Here is what the fuel looked like:
How is that for nasty fuel? That's not emulsified water in there because it never separates. I have no idea...
Here is fuel from another bike refuelled from the exact same gas pumps, at the same time:
Quite a difference, right?
Thinking bad fuel was the culprit, we cleaned the tank, buttoned it up, put in some fresh fuel and took it for a spin. Still cut out. Drat!
So we stripped the tupperware off to examine the wiring. Here is what we found in the main harness:
Burned out solder joint on a large gauge wire that takes some current. I suspect that may be the culprit. Just a few weeks ago we made sure the connector was bathed in dielectric grease. Tomorrow we put in a new pin and hope the problem is solved.
But here is where it gets weird. I get out my shop manual wiring diagram to look where this brown wire goes...and it is not on the plug on the diagram. In fact, the diagram has 14 wires in that plug, but MY bikes have 16 wires. I have a larger brown wire (as in the pic) and a blue wire that are not in the diagram.
However, my diagram does have a brown wire to the ignition switch. While I do not know for sure, I do suspect the burned brown solder joint in the main plug is the problem.
Without a wiring diagram that matches my bikes, I'm kinda shooting in the dark here.
Does anyone have a wiring diagram with 16 wires to the main plug, and not 14? What does this brown wire go to? The blue?
The plug is a 16 pin, with 9 on one row and 6 on the other. The wires on my plug are as follows:
9-row: bl/b - BR - y/b - Y - r/w - B/W - pink/w - lt. green - Br/b
6-row: bl - o/g - b/g - b/bl - o/r - y/g
Any help on what the Brown and Blue wires go to would be appreciated.