2005 600rr- Bad Wiring Harness?? - 600RR.net
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post #1 of 3 (permalink) Old 12-24-2007, 03:55 PM Thread Starter
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2005 600rr- Bad Wiring Harness??

So, I've got a 2005 600rr and have been having trouble with the main wiring harness. Apparently, some electronic component is drawing so much electricity that it is melting one of the ports on the wiring harness which causes the bike to completely shut down spiratically.When the bike shuts down, the only components that loose power are the headlights, fuel pump, and the in-dash lights. Everything else is functional. Over the past year, I have been taking the cap off of the harness and reconnecting it and it has worked so far. However, it is so badly melted now that it isn't safe to ride anymore.
Has anyone ever had this problem before?
Can anyone give any advice as to what the root of the problem might be?
If anyone has a service manual or a wiring diagram for the '05 that would help tremendously!
Any info at all would be greatly appreciated!
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post #2 of 3 (permalink) Old 12-24-2007, 04:29 PM
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I am not sure of the problem but my f4 had something similar where the harness would melt at the alternator plug. You might want to check your RR (reg/rec) that it is still functioning properly. goodluck though.
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post #3 of 3 (permalink) Old 12-27-2007, 08:53 AM
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I've seen harnesses do this when not fully plugged in. It raises the resistance throught the connection, which in turn raises the current draw and creates more heat. The more it happens, the worse it gets.

'05 CBR600RR
'03 ZRX1200R
'72 Rupp Roadster

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