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Thread: TLR - Something Interesting

  1. #31
    Platinum Subscriber JoshCampbell's Avatar
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    Well it turns out the charging Mod was not the issue. Had some buyers coming to look at it yesterday so I decided to let it run for a while. Once it got up to around 210 degrees the tach failed again. After jiggling some wires I found this one to be the culprit. Although it's hard to recreate the problem. Bike and wire has to be hot for the tach to fail, and i have to disconnect it completely before it begins stalling. Not sure why it stalls without unplugging it while riding.

    TLR - Something Interesting-img_1940.jpg
    TLR - Something Interesting-img_1941.jpg

    NOTE: Wire did not look like this when I rebuilt the bike, so its appearance is linked to the issue.
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  2. #32
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    Quote Originally Posted by JoshCampbell View Post
    Well it turns out the charging Mod was not the issue. ....... After jiggling some wires I found this one to be the culprit. Although it's hard to recreate the problem. Bike and wire has to be hot for the tach to fail, and i have to disconnect it completely before it begins stalling. Not sure why it stalls without unplugging it while riding.

    NOTE: Wire did not look like this when I rebuilt the bike, so its appearance is linked to the issue.
    Josh, that looks like the main Loom ground wire spade terminal. It is a common problem area. That could explain some of the odd instrument behavior. It's best just to remove the connector completely and hardwire that ground wire to the chassis at the same point where the negative battery cable connects to the engine.
    January 2012 TLOTM & BBOTM


  3. #33
    Platinum Subscriber JoshCampbell's Avatar
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    Thanks Tony. Is this the ground MOD that I've head about in conversations? If so, any threads on it? Also, is it typical for it to get so hot all of a sudden? I know all about the poorly gaggle mess of ground wires in the loom, but I'm wondering if I did something during the resurrection that contributed to this?
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  5. #34
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    Quote Originally Posted by JoshCampbell View Post
    .......Is this the ground MOD that I've head about in conversations? If so, any threads on it? Also, is it typical for it to get so hot all of a sudden? ........
    Yes, this is likely the mod you have heard about. There is no centralized direction on making this change that I am aware of, but I found this post from years ago that provides the basic outline.

    https://www.tlzone.net/forums/suzuki...ml#post1737077

    I may have some photos of mine floating around, but I also recall rxf610 has posted some photos of the engine case connection and such.

    The reason the wire gets hot is because the Spade terminal, or the wire itself, begins to corrode and is unable to pass the current required by the system. As you know, any resistance to current flow equals heat. Therefore, if you increase the wire size to a larger gauge, and eliminate the Spade connector entirely, it should solve your problem with the loom ground.
    January 2012 TLOTM & BBOTM


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