Electrical woes - opinions?
Hello fellow RVT,ers? I did search first, actually that helped me troubleshoot.
Got myself a bit of a challenge. I've been slowly working on the bike getting her back into great condition since I acquired her. As I said in my intro she's cosmetically rough. As I got in working out kinks (fuses, gauge replacements, turn signal relay, etc.) Anyway, got her out the other night and just got to the first stop in my neighborhood and she died and hasn't ran since. After testing and re-testing I replaced the battery. That didn't work so I replaced the plugs thinking I fouled them out (the old ones still look fine, only tried to crank her a few times.) I'm not getting any FI codes but the gauges load up fine however I have no spark.
Downloaded the factory service manual and started deeper troubleshooting. After thoroughly examining the harnesses and connectors the trouble really began. She was a mess, simple splices,cheap wires, and melted insulation in places. Then I get to the rectifier connectors and find it was burnt at (only visible after disconnecting it.) Further inspection found that the yellow wires on the rectifier were exposed near the base and likely shorted out. That was the first issue. Further testing revealed that the Engine pulse generator has no voltage 0.00 instead of .07 so at this point I am leaning there. My dilemma is that I'm not getting an FI code at all and since the gauges are showing good I'm worried it may be the CDI. Nothing is getting to the coils.
Now, the stand sensor is removed (can't find a bypass.) The position/lean sensor is fine (tested, it does cut the fuel.) The handle switch activates the primer which works (fuel smell is there.) I've bypassed a manual kill switch (maybe custom.) All of my fuses are clean including both 30 amps. The gauges read the neutral gear so I don't think it's that but just to test but it doesn't matter if I hold the clutch.
For now I've crimped connectors on the rectifier but I suspect it's burnt out. Before I start buying replacement parts I wanted to get your take. Should I go ahead and get pulse generator? I think at this point I'm going to try to get an entire harness replacement as well. Thoughts?
Oh happy Father's Day to my fellow dads as well.