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Discussion Starter #1
I have a 2005 cbr 600rr and a few months back my bike would with no warning not want to start the fuel pump wouldn't prime and the headlights wouldn't come on. I narrowed the problem down to a little yellow box on the left side of the bike around the seat area. There was some corrosion around the contacts so i cleaned it all up and pinched the wires to make sure i got good contact and the bike cranked right up everytime. And just lastnight it did the same thing again! When i popped open the yellow box it had melted around 2 wires on the end of the box. What would cause these wires to melt the box? I also need to know what to do to fix this problem i.e do I need to replace this box or just run all of these wires into a larger gauge wire straight to the frame somewhere? I called my local dealer and they couldn't find any ground box so if anyone know's the technical name for the yellow connector that all the green ground wire's go into please let me know.
 
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It's possible that from pinching the wires in a crude attempt to fix a problem, you created a short point.
 

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Any sort of resistance will cause heat to be generated.

To fix it cut the connector off and solder the wires together, then cover with a glue lined heat shrink to prevent corrosion and shorting.
 

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I was thinking about just splicing them all together into a larger wire and running it somewhere to the frame. If i solder them together i will i still have to ground them out somewhere or will they ground to one another? I'm not very good with electrical work I just need a quick fix until i can just buy a new harness instead of chasing a short.
 

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I was thinking about just splicing them all together into a larger wire and running it somewhere to the frame. If i solder them together i will i still have to ground them out somewhere or will they ground to one another? I'm not very good with electrical work I just need a quick fix until i can just buy a new harness instead of chasing a short.
You wont have to ground it to the frame, but it definitely wont hurt!

When you splice them make sure that they are all soldered, not just crimped or heaven forbid twisted. Solder provides a good mechanical and electrical connection and stops corrosion from getting in.

I'm having the same prob with the yellow box how did u pop it apart?
Small screwdriver.
 
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