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ninja 600 electrical

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  #1  
Old 11-18-2007 | 05:11 AM
snowwy66's Avatar
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Default ninja 600 electrical

i have a 94 ninja 600. ---- tach, coolant gauge, fuel gauge, oil light and neutral light don't work. everything else works. i have gone through the book extensively. electrical works everywhere it is supposed to. power from ignition key switch. junction box works. (tried 2 different ones since book gave one failed test which obviously has no wiring and is non existent in bothboxes itself). there are no broken or melted wires. resistance and continuity tests have confirmed that. and nothing is popping up as a possible short between 2 wires. only bad plug on the whole bike goes to the coolant fan switch. but fan works. there is just no power going into those devices. i was able to make the fuel gauge bottom out to E mark by triggering the plug at the tank itself. so i highly doubt the cluster is bad. specially since there is no power to make these specific items work on the cluster. there is no signal to the fuel gauge plug. no signal to the coolant temp sensor. no power to the neutral switch or the oil switch. somewhere there is a loss of hot power not triggering something or there is no ground circuit to make these items work. BY THE BOOK. they all should be working.

P.S.
i am a retired auto mechanic. but i have worked on a few bikes in my time. so i CAN read electrical schematics. this one has me stumped??????????????
 
  #2  
Old 11-18-2007 | 07:10 AM
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Default RE: ninja 600 electrical

found the problem folks. underneath the cluster panel there is a plug that contains a brown wire along with other wires. that brown wire needs power. traced wire down just under gas tank at back of tank. there's power. so somewhere between that point and plug under cluster the wire is broke. rather then tear harness apart to try to pinpoint the exact break of the wire in an effort to terminal back together and retape the WHOLE harness back up. iterminaled a secondary wireinto the brown wire coming out of the ignition switch right at the plug itself. which sits under the gas tank in the middle. it has it's own connection seperate of the FAT WHITE PLUG which belongs to the key switch. i then ran the secondary wire through the frame along side the other harness's andterminaled it into the plug at the cluster panel. problem solved. EVERYTHING WORKS NOW. and plug connectionscan still be pulled apart like normal.
 
  #3  
Old 11-18-2007 | 07:19 AM
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Default RE: ninja 600 electrical

Congrats on the fix. So what caused the broken or burnt wire that needed bypassing?
 
  #4  
Old 11-18-2007 | 02:34 PM
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Default RE: ninja 600 electrical

with no indication of bike being torn apart. have no idea why wire is broken. that's the way i bo ught the bike bout a month ago. with electrical problem AND in not running condition. gallon of gas and simple wire this bike is back together and now ready for the highway.
 
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