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Possible wiring issue?

af1-windy

af1-windy

Cruisin' Guzzisti
Joined
Dec 7, 2011
Messages
193
Location
Hull, England
Having a good look at the wiring in the nose faring, trying to find out why my fog lamps blow the main 30amp fuse when they are turned on. Anyway, I was poking around with a mate :whistle: and he spotted a bunch of wires (red, orange, mainly, I think) exiting the main insulation and fanning out and they appeared to be rubbing on a metal bracket or part of the fairing frame.

Didn't have much time to explore so I'm going back at the weekend to strip off what ever needs to come off to get a proper look, I'll report my findings, if any...

If you look up inside the fairing, left side as you look at the bike front the front, they are above and just to the right of where the indictor housing is. Hope this helps, maybe nothing :) maybe something :huh:

windy
 
af1-windy said:
Having a good look at the wiring in the nose faring, trying to find out why my fog lamps blow the main 30amp fuse when they are turned on. Anyway, I was poking around with a mate :whistle: and he spotted a bunch of wires (red, orange, mainly, I think) exiting the main insulation and fanning out and they appeared to be rubbing on a metal bracket or part of the fairing frame.

Didn't have much time to explore so I'm going back at the weekend to strip off what ever needs to come off to get a proper look, I'll report my findings, if any...

If you look up inside the fairing, left side as you look at the bike front the front, they are above and just to the right of where the indictor housing is. Hope this helps, maybe nothing :) maybe something :huh:

windy
Click to expand...

Pictures would help
 
I know but we were out of time and the bike is 25 miles from me, my ex got the garage... :( bike is at a friends place, I'll ask him to get photos tonight if he gets a minute otherwise it'll be the weekend when I'm next over there.

Out tonight looking at a no start issue on a mates Tuono...

windy
 
I seem to recall there was an issue with the way the wires were run inside the fog lights. SOmething about the way the extra wire was just stuffed in there. But I am not a Stelvio owner, only my cars have fog lights.
Try a search.
 
There IS an issue with the NTX aux lights shorting out and blowing the 30A fuze. Rather than go through the entire song and dance I'd suggest a search here or at www.wildguzzi.com. Lots and lots of info there.

Peter Y.
 
Hi all, I should have made it clear, I have after market lamps, SW-Motech.. they are very neatly wired so I do not think the problem is with the lamp units..

Take a look at the photos, can someone identify what the orange wires are for, one is definitely worn through and look at the metal bracket, it's been shorting against it. I will rip it apart on Saturday and sort it out.

Bike is kept at a mates, he was kind enough to get the pics but he doesn't want to go poking about with my wiring. I've had a look at a wiring diagram but can't spot this multi connector.

First photo is taken from front of bike looking up, to the left is the indicator housing.



Second is a close up of the problem.. we have pushed the wires away from the bracket, they were right up against it.



windy
 
Something else we spotted.. :unsure:

In the second photo there is some wiring in the black sleeve running from the centre of the pic to the bottom right, it's tight up against the silver plastic housing which has already worked it's way through the sleeve so I'll put some padding in between this while I'm in there.

windy
 
Brian UK said:
af1-windy said:
Out tonight looking at a no start issue on a mates Tuono...
Click to expand...
So it's not just Guzzis then. :lol:
Click to expand...

It seems not.. :lol:

We think the problem is not sufficient pressure to the injectors because of a leak in the main fuel supply line. Neither of us are savvy enough to know whether or not the injectors will work with a lower pressure. From what we're told it needs 50psi.

It has good spark, fuel and electrics to all parts needed, it just won't inject..

windy
 
For the orange wire, is that not the trigger wire for the relay for the Motech lights (assuming you used the wiring harness). Seem to recall an orange trigger wire.
 
canuck1969 said:
For the orange wire, is that not the trigger wire for the relay for the Motech lights (assuming you used the wiring harness). Seem to recall an orange trigger wire.
Click to expand...

I hope so because that would explain why the fuse blows when I turn on the fog lights. I've had them fitted a year now and the problem started a few weeks back so maybe it has worn through and it is causing a short when I hit the switch.

I did use the wiring harness and use the switch on the right side handle bar.

Thank you.

windy
 
If you used the switch as the trigger than that is probably it.

When I wired mine in on my 2012 Stelvio, I just cut off the aux light connectors from the bike and spliced in the one from the harness. I used the existing aux light relay to run the lights. It was clean and simple.

Good luck and let us know what you find
 
canuck1969 said:
If you used the switch as the trigger than that is probably it, although you would think it would blow the fuse on the relay harness also???

When I wired mine in on my 2012 Stelvio, I just cut off the aux light connectors from the bike and spliced in the one from the harness. I used the existing aux light relay to run the lights. It was clean and simple.

Good luck and let us know what you find
Click to expand...

I wish it would only blow the fuse on the rely, the 30amp fuse it blows stops the bike running... :(

Have you got time to explain the bit about cutting off connectors and splicing.. :unsure: it's all foreign to me :whistle:

Thanks...

windy
 
I thought it would have blown the fuse on the harness at first, but then thought more about it and edited my post. If it is just the trigger wire it is not fused to the relay so you would have a dead short back through the bike light connector and hence blow your fuse.

On my stelvio, I cut off the original connectors on the bikes wiring harness for the lights. I then spliced in the proper connectors to the Motech lights that I removed from the harness. This gave a direct connection to the lights from the bikes wiring and relay. No harness or Motech relay was needed.

My Stelvio came with Aux lights so it was easy to remove them and put new ones in. I had read that for the pre 2012(2011 Euro) stelvio that unless they came from the factory with lights that the relay was not there. This could be why the Motech harness was used. It has its own connectors to the lights independent from the bikes aux light connectors.

Edit.....need to think more before I write....if you are using the factory switch to turn on the lights then the factory relay has to be there...unless they did some fancy wiring?????


Not a big issue. Just confirm that this orange wire comes from the wiring harness and route it properly. From the pictures it does not look like a stock wire since it is routed without any protection (even for MG standards). This trigger wire is used to switch power to the relay to run the lights. It needs to be hooked up to the power side of you stock aux light connectors. Does not matter which connector your use (left or right light). When you flip the switch, it sends power to the relay which then turns on the lights.

Of course this assumes that this is what it is. Once you confirm it let us know and we can talk you through it.
 
Thank you, that's great. It'll be after the weekend unless I manage to get over one night this week.

Cheers

windy
 
I'm working on a plug and play fog light solution. You plug an in-line fuse between the connectors fused lower than the 30A one. No modifications, 100% reversable.

I've got the fuse holders and connectors on order. Will post when done.
 
Saw your post that you never had stock lights on the bike. I believe that the earlier stelvios had the wiring, but no relay for the lights. Is the orange wire, which I still believe to be the trigger wire, wired directly to the switch. That would explain why there is two orange wires. One to the switch and one back to the motech relay.

Now I am just damn curious......
 
canuck1969 said:
Saw your post that you never had stock lights on the bike. I believe that the earlier stelvios had the wiring, but no relay for the lights. Is the orange wire, which I still believe to be the trigger wire, wired directly to the switch. That would explain why there is two orange wires. One to the switch and one back to the motech relay.

Now I am just damn curious......
Click to expand...

Now I'm even more confused, I didn't use the motech relay, I'm sure there had been aux lights fitted but removed before I bought the bike so I just plugged the motechs into what ever was there.

Bear in mind they worked ok for over a year so either water /damp got in there somehow or there is a short. Hopefully I will get to the bottom of it tomorrow... :S

windy
 
af1-windy said:
canuck1969 said:
Saw your post that you never had stock lights on the bike. I believe that the earlier stelvios had the wiring, but no relay for the lights. Is the orange wire, which I still believe to be the trigger wire, wired directly to the switch. That would explain why there is two orange wires. One to the switch and one back to the motech relay.

Now I am just damn curious......
Click to expand...

Now I'm even more confused, I didn't use the motech relay, I'm sure there had been aux lights fitted but removed before I bought the bike so I just plugged the motechs into what ever was there.

Bear in mind they worked ok for over a year so either water /damp got in there somehow or there is a short. Hopefully I will get to the bottom of it tomorrow... :S

windy
Click to expand...

Did you change the plugs.....

The Motech are an entirely different plug than the stock setup. I am guessing that the previous owner may have used the relay.

Let's see what you find this weekend.
 
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