Daytona 600’s With Electrical Issues.

Jerryh · May 6, 2024

Hi I’m new on the forum, can anyone help, I have two 03/04 Daytona 600’s both with the same electrical issue,
When the ignition is turned on all is well with regards to the electrical system, rev counter will do a full sweep of the clock, bike will start, the clocks and rev counter will almost instantly loose power and stay that way.
If you pull the lighting fuse in the front fuse box the clocks and rev counter both power up, so I replaced the fuse and pulled both head lamp plugs, this reduced the load on the electrical circuit and clocks came back on, then allowed the bike to heat up and when the fan cut in we lost the clocks rev counter once more, I’m really struggling to work out where the issue is I’ve inspected both handle switches, no obvious shorting or damage, unplugged rear lights no difference, I have checked the stand switch that seems to only work with the stand up but I really don’t know if it’s capable of causing this issue, if the front break is pulled I loose the clocks, due to the load of the rear lights I presume and lastly the charging system is working correctly with 13.8 to 14 volts on the battery with the bike running, stator and rectifier have been independently checked and are definitely fine.
If anyone can possibly help I’d very extremely grateful.
Jerry Hart
Jersey

Alan1983 · May 8, 2024

Hello Jerryh,
It sounds like a bad/corroded grounding connection at the engine block or a worn battery (sulphated plates).
It might be useful to check the battery connections for corrosion, and the wiring harness for scaffing/damage
If you rev up the engine does the charging voltage goes up to 14,6 Volt?

Jerryh · May 10, 2024

Hi Alan,
Thanks for taking the time to reply, it’s been quite a painful journey with this fault,
Basically everything checked out ok regarding the changing system, also the main earth has been checked, iv had the loom apart, switch gear, stand switch etc etc, I even purchased a second bike for very reasonable money in the hope that i could make one good bike out of the two of them !!
The key thing with this story is when we purchased the original bike it had been basically rebuilt and part of that work was a new fuel pump, the second bike wouldn’t stat straight away then finally catch on the 3ed or 4th attempt, fuel pump issue! So put the tank from the fist bike on it an lo and behold it ran straight up! BUT with the same electrical issue as bike 1 ! Basically the new fuel pump is faulty pulling down the system voltage, when you start unplugging systems like lightning things return to normal as the load/voltage is exemptible but soon as something like the fan cuts in you lose the dash once again. Thanks again for your reply to the question.
Kind Regards
Jerry

Alan1983 · May 13, 2024

You mentioned that the bike is basically rebuild, does that also involved any electrical parts?
What you could try, checking the system voltage of the ECU with the means of Dealertool or Tuneecu.
They both have a diagnostics tab which gives the ECU system voltage, at the same time measure the voltage on the battery connections, and observe the voltage drop on both , when there is a load change.
If there is a bigger voltage drop on the ECU then on the battery, you can follow the rout back to the battery, to see where you are loosing the voltage due to excessive resistance.
I don't know if you have an electrical diagram , if not I have it attached to this post.
I hope this will make fault search a bit easier.

Jerryh · May 14, 2024

Alan,

Thanks for your time in responding to my questions, read the post above, I have tracked the problem down to a fuel pump, the issue has been resolved with a new pump unit fitted.

thanks again for your help
Kind Regards
Jerry