- Jan 16, 2015
I think that may explain all of your issues !Finally got the opportunity to fit the new battery and swap out the relays. Interestingly three of the under seat relays were numbered by hand. Not sure why given they are identical - related to cable attachment during assembly maybe.
Fitted the new Shorai battery. Spaced the battery for height to match the original battery and so the strap provided security. Put longer bolts in the posts, with spring washers. Was‘nt happy with security of the OEM shorter post bolts. Taped the Shorai charging cable to the side of the battery/box to ensure lowest profile. Tank back on, reconnect, turn key, nothing. Completely dead.
Tank back off; it is pretty easy with a little practice and I’ve had a lot! Checked seating of relays etc, all good. Battery fully charged but no power to bike. Pulled the 30A fuse from the positive cable housing and checked resistance, all good. Manipulated the positive cable with ignition on and ‘voila’, ignition lights came on, relays click, fuel pump primes. Gently manipulate the cable again and the sound of shorting and ignition off. This doesn’t explain all of the symptoms of my charging/ electrical difficulties but obviously a significant contributing factor.
A closer look at the positive cable shows what appears to be some sort of crimping damage just below the terminal boot and further damage under the boot, adjacent to the terminal. The crimping damage is a mystery. The under boot damage I can only assume comes from contact with the tank. I was very careful when packing the Shorai for height in the past, to match the original battery, noting that as such the battery strap is under minimum tension. That said this must be a vibration/rub damage from the tank. How it transferred through the rubber boot is also a mystery.
With the battery so mounted, when viewed from the underside, lifting the tank slightly (no fixings in place) and lowering again, the tank does contact the battery and lower the tray slightly. My guess is this is how battery trays have been failing, under permanent tension and through vibration. If I lower the battery by removing packing the strap has no tension.
So my immediate problem is the replacement of this cable, which routes under the tank/frame and disappears into the main wiring loom wrap. I guess this terminates at the starter motor but may also feed other parts of the electrical system. I have (very) limited auto electrical knowledge. Is the replacement of this cable/section going to be difficult - it seems so? Am I better trying to section in a new terminal/ fuse cable end to the existing wiring? Should I be getting out of the way and giving this repair to my dealer? Thanks Tony/guys - any input would be gratefully received, as ever.
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