2001 FI Electrical Burning Smell

Hi everyone,

2001 (2003 on License Plate) VFR800FI

Recently developed an electrical burning smell which seems to emanate from the right side under the tank. Revs seem hesitant too, but fuel economy seems normal. I followed the instructions on here for checking the RR and Stator. They all seem normal and within spec, it's a new battery too.

• Battery 13.7V (engine not started)
• Battery 15.42V (5K rev)
• Battery ~15.1V (5K rev / Hi Beam)
• No continuity from Stator wires to ground (measured from loom side)
• Measuring Y1-Y2/Y1-Y3/Y2-Y3 gives between .1-1.0 Ohm
• Red/White wire to ground gives voltage (measured from RR side)
• Green wire to ground gives continuity (measured from RR side)

Cleaned the ground contacts on the RR. Cleaned the Stator wires and the other plug.

Could it be the HT coil burning up ?

Thanks in advance,

Dan.

 

That voltage is way too high at 5K and it will boil your battery over time. Seems to me the RR is bad so you may want to check the wiring very well.....

 

Agreed - you are on the high end at 5K rpm. (Some will go off the charts at 17 -18 volts). Although, I thought I recalled seeing somewhere that 15V +/- was ok?

I'm wondering why your battery is at 13.7 without the bike started. Each of the 6 cells holds 2.1 to 2.2V, so you should be at 12.6 (min) to 13.2. I'm not saying its wrong or a problem (maybe it is???), but it is interesting to see it that high without being started.

Sit tight. Someone will be along to better explain in due course.

 

Oh an I would also check those readings again with another meter just to be sure. I have found out some volt meters are not very accurate!

 

Hmmmm, where did you find that from CRFan? lol

 

LOL...let's just say, you learn something new every day! hehehe otstir:

 

Yes that is indeed correct. In my case it's...don't quote voltages from memory !

OK I have just been down to the bike and measured the following :

Rest - 12.92V
Idle (2K) - 14.4V
Idle & Hi Beam - 13-12.8V
5K & Hi Beam - 14.3V

One other thing to add into the mix. I recall when riding at night on full beam, the headlight sometimes drops to dipped then back to full automatically.

Cheers

Dan

 

Seems to me that your RR is functioning as intended so no worries there. It does seem like you have some other wiring issues going on though. The headlights should should not go back to low beam by themselves . Check that switch and check your grounds, etc.

 

Unrelated, but is that your idle when cold or warmed up? Normal idle is only 1100-1200. Maybe go a little higher to say, 1400 or so. But 2000?

 

Pull the seat and rear bodywork. Look closely at the connector for the RR before you ride again. Better safe than sorry.

Jose

 

Hi all

I checked the RR connector on Sat, it seemed ok. The burning smell definitely seems to be coming from the front right of the bike. That's what makes me think that it's the HT coil. The smell isn't strong, but it is definitely there.

From what I can see and read, the RR seems OK.

Incidentally, the cold idle is approx 1500-2000 for about a minute...then it drops down to around 1400.

 

I keep my idle at 1400 too....charges better there and seems to have better off idle throttle response. I would takes the right side fairing off and investigate.

 

Hi everyone,

Well it may seem like an aeon since I posted this, but well life has a habit of getting in the way !

I found the source of the problems. The smell was driving me crazy, and then a thunderbolt of inspiration hit me like lightning ! I took the connector off the right headlight, and immediately found the issue:



I have read that there was a sub harness recall on the 6th Gen, but this is a 5th Gen.

HELP !!!

 

Hi Tinker, thanks for this. I am in the UK, so can you advise which connector I should purchase please ?

 

They are the H4 connectors, you can buy them at your local automotive shop. I bought a set of two for $12 USD.

 

So, an update.

I replaced the bad H4 connector, so I have a working right headlight now. However my problems continue !

I have noticed melting on the left headlight connector now, on the ground. Also the high beam seems to be switched on even when the low beam is on. It's like the two lights do the opposite of what they should..if one is on low the other is high. According to Haynes the wiring is correct.

Using a meter I have a ~20 ohm resistance from the high beam to ground. Is this correct ? Are there any typical locations where the wiring can burn out ?

Plus I think the RR is finally dying. It clicks and resets the clock when starting, even if the battery is fully charged. Measured on the battery is around 14.6V at 4000RPM.

Beginning to lose patience with this bike...

 

I have a 5th gen and when my r\r was bad it blew my headlight bulbs. Luckily it didn't fry my connectors. But the other thing was my battery would show perfect voltage but it would fry my cold cranking amps making my clock reset like yours. I was losing my patience as well but after a new r\r from ricks and everything is good again.