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Go Back   FZ1OA Message Board > FZ1 & Fazer Owners Association > FZ1 Problems & Issues > Gen 1 Problems & Issues

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Old 04-14-2019, 05:44 AM   #1
dizy
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Electrical issues help needed

I have 2003 FZ with an electrical issue. When I use the turn signal, high beam switch and if can comes on, the taxi needle drops below 0 and back up several times. Also the warning lights on Rach also flicker on and off. When the fan comes on, same thing happens. The bike runs great, no issues with engine. I did notice that the fan does not come on after few minutes of idling in neutral gear. When the fan does eventually come on, the fan goes on and off quickly along with tach needle acting up. The big white connector was replaced, and battery is almost new. Starting is not a problem. O m worried that thus problem will cause engine over heating since the fan seems to not stay on like it should. Any hel0 appreciated.
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Old 04-14-2019, 05:48 AM   #2
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Sorry with misspelled words. I meant Tach and speed gauge flickering, needles going up and down, warning lights blinking when ever I use turn signal switch, high beam switch and when fan comes on.
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Old 04-14-2019, 06:11 PM   #3
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It sounds like the wiring harness frame ground has developed some resistance. Every time the current load changes, the voltage reference changes also. It could also be a ground for the gauge cluster that's the problem.

Don't just check to see that connections are tight, disconnect them and clean the surfaces on both the frame and terminals.
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Old 04-14-2019, 07:24 PM   #4
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Lift up gas tank. Secure it with a 7 foot piece of rope hooked over the grab handle ends and under the tank hold-down bracket. Like this.

Remove the inner fairing panels and the front fairing. Be careful to not break the screw mount points in the fairing. Once all that is off, disconnect every connector you can see, one by one. Clean each with some contact cleaner (or WD40) and whatever small brush you can use to get inside the plugs. Reconnect each one a few times. Blow out with compressed air if you have it. The connectors can only go in one place each, so there's not a lot of danger of plugging them back in wrong.

If that doesn't solve the problem, flush the ignition switch with WD40. Spray a ton of it in there, working the key in and out and turning the key a few times. Put a rag under it to catch the stuff that comes out.

Report back after all that.
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Old 04-15-2019, 06:03 AM   #5
dizy
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Thanks for the advice. Will try your recommendations. Can the turn signal/high beam switches cause the problem too? Are the in the same circuit with gauge cluster
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Old 04-15-2019, 09:37 AM   #6
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The drivers are in the gauge cluster but the switch gear on the handlebars can also get dirty inside. I doubt that's the problem but it won't hurt to open them up and clean them.
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Old 05-13-2019, 05:42 PM   #7
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Have you found the issue? I am having the exact same issues, got stranded on the side of the highway when my battery died. It turns out the inline fuse holder I installed as part of the "white connector delete" had completely melted, I don't know yet though if it was just a poor quality part or if its part of a bigger problem
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Old 05-14-2019, 07:47 AM   #8
Dean Dinnetz
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And I had the same problem, about two years ago. Fresh battery, the gauges went crazy, bike stopped and started, and then the bike died. The %&%$#* connector had almost burned out. Went to the place I was staying with pals on our tour, and we hard wired all five wires together. No more problems period, since.

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Old 05-16-2019, 04:35 AM   #9
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Found the problem, it was the rectifier, it is not working. My FZ died on me while going to work, had to be towed back to home. Bad day yesterday. The white connector was replaced long time ago, so that is not the problem for me. You guys should check rectifier, many YouTube videos to show you how to do it. I guess there is a big issue with charging sustem with this bike, not very happy with Yamaha.
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Old 08-09-2019, 12:47 PM   #10
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I just has a similar issue. I was on a four day trip in SE Ohio, out on a day ride about 100mi from Marietta where I was staying. My dash lights started flickering, the two needles dropping, when I'd turn the high beams on, or turn signal, the dash would go completely dead. A few minutes later, the bike sputtered then died. Battery dead. I was in a pretty remote area west of Athens.
After looking under the tank, the posi-connectors I used to replace the "white connector", had failed. Two of them had melted together, and two of the wires breached. I was about ten hours total from home. This was the first long trip I had made on the FZ1 since replacing the "white connector" a few months prior.
To back up, I wasn't having issues with the bike before I replaced the white connector. I had read about it on this forum, so I replaced it as a preventative measure. I now wish I'd left it alone. I do not now why the posi-connectors failed. Maybe I made a mistake somewhere.
Anyway, I was blessed to have a very kind older couple help me out, and put me up for the night. Then arranged for me to rent a U-haul to get me and my bike home.
This was last weekend. I need to get in there now and replace the connectors again. Thinking about just using bullet connectors or soldering them together and shrink wrapping them. I just hope it didn't take out my rec/reg or stator. By the way, this is an 02' FZ1 with over 100k miles. First time she's ever left me on the side of the road.
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Old 08-09-2019, 12:51 PM   #11
dizy
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Sorry to read about your FZ Iceman. I'm still hesitant to ride my FZ1 too far. I think the charging system is poorly designed, and quality is very poor.
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Old 08-09-2019, 01:05 PM   #12
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Quote:
Originally Posted by Iceman63 View Post
This was last weekend. I need to get in there now and replace the connectors again. Thinking about just using bullet connectors or soldering them together and shrink wrapping them. I just hope it didn't take out my rec/reg or stator. By the way, this is an 02' FZ1 with over 100k miles. First time she's ever left me on the side of the road.
The connectors you used may just not have been up to the task. I'd probably look for the one's suggested by Eskort if I had to touch the white connector

http://www.yamahafz1oa.com/eskortsde...lacement.shtml
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Old 08-09-2019, 02:23 PM   #13
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Mostly high quality connectors will cure the problem.

In my opinion the root cause is the poorly designed wire assembly. The system is on the edge. The regulator is placed far away from the battery, with quite long cables towards it, and sharing the ground line with other consumers. Adding some aging of the cables it might start to oscillate and by this overload the "white cables" with excessive currents.

My suggestion would be to also cut the black and red cable directly at the R/R and connect them directly to battery.

At least that is my "oscillation" theorie. Based on some strange oscilloscope measurements I've seen in the past.
Any opinions of the experts?
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Old 08-09-2019, 02:34 PM   #14
wotnnc
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At around 26000 miles while doing a valve check, I saw one of the AC legs discolored from heat on my 05 so I cut everything out, crimped and soldered all five wires, then put heat shrink over each one. Fixed my 04 the same way before it ever had an opportunity to give a problem. If either rectifier ever needs to be replaced I'll use a MOSFET type and connect it to the harness on the bike the same way. That's a really tight spot which might be why the OEM connector is undersized anyway. At the stator end, the connector is quite a bit larger.

Last edited by wotnnc; 08-09-2019 at 03:00 PM.
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Old 08-11-2019, 12:50 PM   #15
Iceman63
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dizy, I'm not trying to hyjack your thread, just staying on subject.
Yesterday, I cut out the connectors that I used to replace the "white connector". One of them had melted really bad. I think it was one of the white wires too....could've been the red, can't remember. I soldered and shrink wrapped them all back together. While doing all this, I re-charged the battery.
She started right up. But was idling rough; which, actually started the morning before the break down. I had written that off as a possible carb issue, or trashy gas. But I'm starting to think it's something else. When I bring the revs up, it smooths out a bit(all this is in neutral in the garage), but there's some popping going on. Also, when I turn on the high beams or turn signal, the cluster lights and tach/speedo needles take a quick dip and come back up. Also, how hot to the touch should the rec/reg get? I know it gets hot. But it was quite hot. I've never really touched it before while the bike is running.
So I now need to grab a multi metter and check charging voltage, etc. I'm thinking either the rec/reg or stator is going.
Can a bad rec/reg take out the connectors?
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