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GSXR Wiring Harness Issues?

3872 Views 39 Replies 9 Participants Last post by  BillV
I have a k7 gsxr 600. So one day im riding and my bike randomly cuts off. Apparently my ecu was fried so I got a new one, bike turned over once and worked, but wouldnt turn back on after it was turned off. Now, the bike wont completely turn over and my fuel pump isnt priming. Me and my buddy have used our multimeter and circuit tester everywhere and the bike seems fine. Anybody have any idea of where to go from here? I replaced my battery and rectifier after the wires were fucked (for the r/r). My dash doesnt come on either, seems completely dead but I get the indicator lights, hi and low beam dont work either. Ive done all I can think, I dont want to take it to a shop but im out of options lol.

Could my issue be the entire wiring harness? Is that common? I cant find a single thread where someone has had my issues.
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and battery, again, batteries can appear good on multi meter but not be strong enough to clip starter relay and prime pump, put a jump from a car on it or a battery charger after checking all of above from Geek and it still has no crank...

how many volts and amps did battery show, are terminals clean solid with good contact, ground to engine solid and clean?
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trace that dead wire until you find it active, do you know how to perform leak tests, or dead ground test, continuity test? all simple with multi meter
leak test, dead ground test, continuity test, all the same, however a break test is somewhat different, I wire can have a partial break in it, or a full break, a full break would equate to a continuity test, then you have a break in a wire that's grounding out on metal, maybe a partial break, partial ground out, then some behave intermittent

I have a toaster that has one side of the lead broken, dead break, but I pull the toaster along the wall sothe lead is a 90 right off the plug, the break is right at the plug like someone got as close to the plug as possible and hit it with a razor clean through, however the wire protrudes just a smidge o n both ends, cuz I am lazy I just move the wire so its lined up then put tension on it so contact is made, long as I dont move toaster it works day in day out..

it didn't start out a clean break, started out where it didn't work at all and no visible break, but I had noticed at a certain angle it would work, then one day it sparked bad and cut clean, I just moved it around till it made contact and then pulled onthelead till it stayed in place and been using it that way since.. too lazy to get a simple 2 prong plug at home depot for $2.89 and fix it I guess? for the life of me I have no idea how it happened, did I nick it with a knife? was it defective?

so wires can have a complete break in them and the insulation can be in tact, toaster did this, something made it arc and the heat burned through the insulation and made a clean cut.. they can also chaff insulation creating a ground out, leak, then obviously they canbreak clean through insulation and all, sometimes the raw end grounds out or even touched something else and activates it, rarer but known to happen..

so you have to test these leads for the various situations, first do a continuity test, see if its carrying any juice or has a clean break in it.. then on to the others..

a video runs through continuity in a simple manner

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you have isolated the wire to where the signal is dead, now you need to trace it back to find where its live again, somewhere in the signal, could be a bad pin in a plug, could be a break in the wire whatever, so you need the schematic its inthe service manual or maybe someone has a nice large color one?

find where that wire ends up, at a connector plug, or a switch where ever then test the wire at each end for continuity or a break or ground out..

pretty simple once you locate the other end and keep going backwards until you find a live signal, then you know form there forwards is where the break or whatever will be, again may be a broken pin in a connector plug, maybe be a bad switch or sensor, maybe be chaffed or broken wire..

you must test teh circuit to see what it's doing? is it leaking, completely dead? and wiggle the wire or harness around as well when you do test, could bea toaster issue?

you will find and fix it
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then there is the tool you can use to find exactly where the break is..

simple continuity test in its simplest form.. every multimeter has a continuity test on it, it beeps like this when its good, there are ways to test partial breaks using ohms and other testers

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you need to download the service manual so you can do pinout research, determine which pump lead is for the 12 volt power supply to run the pump, keep tracing it backwards to find out where its losing juice, maybe be a pin in the connectors, chaffed or broken wire, gotta trace it..

also once you determine which pump leads are + and - you can connect a 12 volt power supply to run pump check if its faulty.. easy

2 large alligator clips clamped to the battery + - supply then 2 smaller alligator clips to connect to the pump + - leads works great..

all kinds of youtube videos show you how to perform wire break tests so forth, but you must trace it back to where it does have power then figure out why its not making it to the pump, you check fuel pump fuse?

also service manual will have a troubleshooting section you lookup by symptoms

look up like "#23. battery has 12 volts, key on, fuel pump does not prime" then it walks you through in an organized manner to determine where the fault is..
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