Smoking wires / won't start - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
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post #1 of 14 (permalink) Old 10-20-2016, 06:08 PM Thread Starter
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Smoking wires / won't start

Hello everyone,

Last night I was driving home from work and stopped at the liquor store for a 6 pack. I wasn't in the store for more than 5 minutes and when I attempted to start the bike i got a hint of it turning over and then lots of clicking. I waited about ten minutes and tried again (thinking that it may be some hot start issue) and same thing happened except this time I could smell burning plastic or wires. It was dark and so I walked it the 1/4 mile back to my apartment. This morning I tried to start it again and this time I could see smoke coming from the wiring harness. I've attached a picture to show where the heat is burning through the electrical tape. I looked at the battery terminals and noticed that the metal piece that connects the negative lead to the frame (I'm guessing to ground?) had broken. Could that be causing a short and the wiring system to overheat? Also, what part number is that? I will order it from bike bandit. I already purchased a new (used) wiring harness from a 2004 that is in good condition to replace the old one. Could there be another issue causing wires to melt? The battery, stator, and regulator were all replaced about 5,000 miles ago. The regulator has not been relocated yet, though. Any help is greatly appreciated!!
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post #2 of 14 (permalink) Old 10-20-2016, 06:17 PM
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A faulty ground can cause all sorts of hub-bub, but a short like that makes me think something rubbed through the insulation and touched the frame. Once that happened, fireworks!

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #3 of 14 (permalink) Old 10-20-2016, 07:42 PM
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without a proper ground (the cable that broke), then you will get all sorts of weird shiat happening.

fix the ground, and cross fingers, it may just start up and work. After all, everything but the starter is fused, so you should be 'safe'

but I would definately look at the wires there where it started to cook and double check them

2005 VN750

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post #4 of 14 (permalink) Old 10-20-2016, 08:15 PM
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yup that ground,when broken,positively charges the gas tank sender,causing it to short out.been there with mine.

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post #5 of 14 (permalink) Old 10-20-2016, 09:04 PM Thread Starter
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Cool. Do you guys know what piece that is that broke? I'm looking at the schematics and can't seem to figure out what it is.
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post #6 of 14 (permalink) Old 10-20-2016, 11:43 PM
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Quote:
Originally Posted by ClimbBikeBrett View Post
Cool. Do you guys know what piece that is that broke? I'm looking at the schematics and can't seem to figure out what it is.
That's a pretty impressive insulation cutter you've got yourself there.

Can't find a part number for it, but:
86 KAWASAKI VN750 VN 750 VULCAN BATTERY CABLES #18 | eBay

There are several postings for battery cables that would NOT work too.

Seems like it might be easiest to just hit up the local auto parts store and get a new heavy-duty eye connector that you could replace the broken metal with.

1992 US-nonCA * tuxedo mod * r/r relocated

Vulcan slang for newcomers
Service Manual Download
Wiring Diagram + annotations * still undergoing revisions, but still more useful than the generic one. Let me know if you find mistakes or think something additional should be added
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post #7 of 14 (permalink) Old 10-21-2016, 12:25 AM Thread Starter
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So it's called an eye connector! Alright, I'm getting closer to figuring this out. Thank you very much for the link. I'll head to the dealer tomorrow and if they don't have the connector I will purchase the one on ebay. You guys are amazing! Thank you! Btw, even though this machine is old and cranky I wouldn't have chosen a different bike! Love it!
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post #8 of 14 (permalink) Old 10-21-2016, 12:39 AM
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You can make your own ground cables or buy them pre-made as well at local auto stores. The little black/yellow cable just needs to be grounded, as well. You can crimp on an eyelet to it and put it direct on the negative post along with the main ground.

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #9 of 14 (permalink) Old 10-21-2016, 08:09 AM
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should have that ground in the wiring harness ya bought

Sent from my LGL34C using Tapatalk

ONE RATS ASS GIVEN PER POST
Support your local FREEBIRDS MC
1986/5 Vn700/750 Frankenfook cross eyed bitch "Mellisa Fayhe"
I am a BIKER and i'm proud.FREEBIRDS MC CENTRAL NY

lowered with progessive 412 10" shocks
rejetted for K/N Pods part#rc 2340
sportster seat

'I didn't lose my mind.i gave it away

BRING BACK WOLFIE."Peace and Carrots"RIP
"And I'm free...as a bird"John Lennon Free as a Bird
"I only carry when I have my pants on"Joe Robinson RIP aka Old Dog
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post #10 of 14 (permalink) Old 10-21-2016, 02:56 PM Thread Starter
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Doc, you are probably right! It is in the mail, so we shall see on Monday. I bought the wires and eye rings that I need to make a new ones and I'll do that at some point this weekend. It would be cool to get it running again, so that I can hold off on putting in the new wiring harness until next weekend.
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