pdfruth
P.D.Fruth
I guess I can post in here... Now that I've FINALLY tracked this one down, it's a "known" problem. 
I've been having a really annoying intermittent problem, with a fuse blowing, for quite some time. In my case, it was always the same fuse. Specifically, the fuse that powers the instrument cluster + tail lights + headlight aiming motor + hazards + position lights. I'd be driving along, everything working as expected. At some point, I'd look down, and the instrument cluster would be dead (no RPMS, speed, temp, fuel, etc.) Upon checking the fuses, I'd find the fuse blown again. Replace the fuse, and everything would be fine again for awhile (sometimes months). This has been going on for a year or so. All the signs of a wire rub somewhere (aka chafed wire). Well, I finally got a chance to strip the bike down, completely naked, to hunt for the problem.
I finally found it. Thought I'd post here, in case others come across the same, or similar, problem.
There is a wire bundle, for the switch pod on the left handle bar. The bundle has 17 wires in it, and is encased in a light-weight rubber sheath. The bundle runs down the left handle bar, next to the steering stem, and then under the hydraulic line for the clutch. The hydraulic line is affixed to the frame such that it runs along the outside of the left, upper frame spar, and maintains about a half inch (or there bouts) clearance away from the frame. Honda has routed the afore-mentioned wire bundle under the hydraulic line (so it's pinched between the hydraulic line and the frame). A very tight space to try and route a rather thick bundle of wires. Anyhow, it was a sufficiently tight squeeze to cause the rubber sheath of the wire bundle to completely rub though, and then through the insulation of one of the wires (the black/brown wire in this case). Thus, when ever I'd turn the handle bars just right, there was a direct short to ground, via the hydraulic line.
My bike is a 2003 ST1300 ABS with 20K+ miles.
I'd bet that there will be others out there, who will eventually have this problem too. Or problems with similar characteristics (i.e. intermittent blow fuses). It's just a matter of time.
Looking at the wiring diagram, I'd say that there is a good chance that other complaints might include intermittent blown fuses for;
- Horn
- Hazards
- Turn signals
- Head lights
- Instrument cluster
- Tail lights
- Screen adjuster
My Fix;
After taking the wire bundle apart and fixing the chafed wire, I re-routed the wire bundle. Instead of routing underneath the hydraulic line, I routed it over the hydraulic line.
See attached picture of the effected area.
Search terms (so others will find this thread when searching);
Intermittent blow blown pop popped fuse chafe chafed chafing rub rubbed dead dash instrument cluster screen adjuster head light tail lights turn signal signals horn aiming motor
Maybe the mods could make this a sticky
EDIT: annotated the photo with a clearer indication of the area where the wire chafe occurred on my bike.
I've been having a really annoying intermittent problem, with a fuse blowing, for quite some time. In my case, it was always the same fuse. Specifically, the fuse that powers the instrument cluster + tail lights + headlight aiming motor + hazards + position lights. I'd be driving along, everything working as expected. At some point, I'd look down, and the instrument cluster would be dead (no RPMS, speed, temp, fuel, etc.) Upon checking the fuses, I'd find the fuse blown again. Replace the fuse, and everything would be fine again for awhile (sometimes months). This has been going on for a year or so. All the signs of a wire rub somewhere (aka chafed wire). Well, I finally got a chance to strip the bike down, completely naked, to hunt for the problem.
I finally found it. Thought I'd post here, in case others come across the same, or similar, problem.
There is a wire bundle, for the switch pod on the left handle bar. The bundle has 17 wires in it, and is encased in a light-weight rubber sheath. The bundle runs down the left handle bar, next to the steering stem, and then under the hydraulic line for the clutch. The hydraulic line is affixed to the frame such that it runs along the outside of the left, upper frame spar, and maintains about a half inch (or there bouts) clearance away from the frame. Honda has routed the afore-mentioned wire bundle under the hydraulic line (so it's pinched between the hydraulic line and the frame). A very tight space to try and route a rather thick bundle of wires. Anyhow, it was a sufficiently tight squeeze to cause the rubber sheath of the wire bundle to completely rub though, and then through the insulation of one of the wires (the black/brown wire in this case). Thus, when ever I'd turn the handle bars just right, there was a direct short to ground, via the hydraulic line.
My bike is a 2003 ST1300 ABS with 20K+ miles.
I'd bet that there will be others out there, who will eventually have this problem too. Or problems with similar characteristics (i.e. intermittent blow fuses). It's just a matter of time.
Looking at the wiring diagram, I'd say that there is a good chance that other complaints might include intermittent blown fuses for;
- Horn
- Hazards
- Turn signals
- Head lights
- Instrument cluster
- Tail lights
- Screen adjuster
My Fix;
After taking the wire bundle apart and fixing the chafed wire, I re-routed the wire bundle. Instead of routing underneath the hydraulic line, I routed it over the hydraulic line.
See attached picture of the effected area.
Search terms (so others will find this thread when searching);
Intermittent blow blown pop popped fuse chafe chafed chafing rub rubbed dead dash instrument cluster screen adjuster head light tail lights turn signal signals horn aiming motor
Maybe the mods could make this a sticky
EDIT: annotated the photo with a clearer indication of the area where the wire chafe occurred on my bike.
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