Author Topic: Ignition switch wiring failure  (Read 502 times)

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Offline Rexani

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Ignition switch wiring failure
on: 08 September, 2021, 09:13:36 AM
Hey guys, I bought this Tiger 1050 2 months ago. So far I had to replace the radiator (Damn was that expensive), new battery, all regular service, breaks ...

Since yesterday, I noticed during slow riding, my headlight would turn off. After further investigation, it looks like the wiring loom going to the ignition switch is very tight and wiggling it with the switch on the on position, would turn the light on and off. When the light is off, the starter and high beams won't work, the horn does. I hear the starter relay engage, but the starter isn't turning over at all. When the headlight is on, all works perfectly. While riding if the light turns off there are no real issues except for no headlight, which happens when I turn sharply and is dangerous when riding at night.

This morning when I went to park it at the office, during a slow left-hand corner, I heard the horn go off for a split second. Removed the cover of the wiring loom but see no visible damage.
Removing the ignition switch to have a good look at the internal soldering looks like a pain in the butt to do.

Can someone point me in the right direction as to what could be the issue / how to get a good look at the internals of the ignition switch? Already spent a lot of work / money to get it in good condition, but every time something is fixed, another issue seems to come up.

Stripped the mantle a bit but nothing really visible ...



#1

Offline Paul2bikes

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Re: Ignition switch wiring failure
Reply #1 on: 08 September, 2021, 10:03:05 AM
My money would be on the ignition switch.
Also: '16 Tiger 800, '95 Yamaha Serow, '58 Ariel FH.

#2

Offline Rexani

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Re: Ignition switch wiring failure
Reply #2 on: 08 September, 2021, 01:15:12 PM
*Originally Posted by Paul2bikes [+]
My money would be on the ignition switch.

Thanks! Just went on to strip the bike to get the lower part of the ignition switch off. The brown wire was broken inside the insulation so damage wasn't visible to the eye. It was with a multimeter tho. Will add a comment tonight after work with details how I fixed it, took some pictures in case it could help someone else. Damn shear bolts, had to use the Dremel to cut a groove in them to get them out

#3

Offline Rexani

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Re: Ignition switch wiring failure
Reply #3 on: 08 September, 2021, 02:14:00 PM
Edit: Noticed I didn't specify which tiger it was, it was a Tiger 1050SE from 2012
Soooo, this was for me about an hour of work. My first goal was to locate and unplug the plug for the ignition switch, which was located underneath the air box.

See picture:


After it was unplugged, I had to figure out how to remove the lower part of the ignition switch itself, which contains the wiring and allows me to take it fully off the bike to start diagnosing + attempt to fix it.

The lower part is fixed to the upper part with 2 shear bolts. I removed them by cutting a small groove at the top of the bolt which enabled me to fit a flathead screwdriver on them and get them out. (I used some zip ties to keep the other wires out of the way so I don't cut them by accident while using the Dremel)


Once both are off, the lower part slides off the spindle coming from the upper part.

After getting the wiring loom and lower part onto my workbench, I started testing contingency and found out that the brown wire was not conducting through. So I slid my fingers across the cable to try and feel where the cable might be split. Which worked pretty well to be honest. After feeling something off, I cut a piece of the insulation off, and to no surprise, there was a void in the middle of where I felt the little bubble.


I cut off a small part of the cable, stripped the ends and crimped it together again. By some luck the part I cut off, and the crimp I used were the same length.
Added some electrical tape around the crimp, taped around the loom again and put the lower part back together


It turned out pretty clean so put it back on the bike.



Put the bike back together, making sure all cables are routed correctly with plenty of play for turning the handlebars and it starts up perfectly again! No headlight turning off anymore!

Hope this helps someone else :)
Last Edit: 08 September, 2021, 02:42:48 PM by Rexani

#4

Offline Paul2bikes

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Re: Ignition switch wiring failure
Reply #4 on: 08 September, 2021, 03:43:50 PM
Brilliant, great when it all comes together.  :031: Have a beer.

One for the stickies eh.
Also: '16 Tiger 800, '95 Yamaha Serow, '58 Ariel FH.

#5

Offline Zevk

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Re: Ignition switch wiring failure
Reply #5 on: 08 September, 2021, 10:11:46 PM
Fantastic outcome!  :046:

My disconnection was the plastic connector plug, under the air box.

The white wire was intermittently loosing connection inside the plug.

I cleaned up the inside of the connector with wd40 compressed air, then die electric grease, zip tie securing the plug connection, acrylic automotive hot glue over the wires at the connect and zip tied the harness, to the frame, so it doesn’t move as much

If this happens again, I have posi locks connectors I can use with short jumper wires, or I will just solder the connection permanently if it happens again, as the only reason to disconnect is if replacing the ignition switch. 

For such a critical component, triumph should have spent a few extra dollars and made the harness of better quality ie thicker and longer wires and heavy duty plug connector imho of course… :192:



RV90, XL250, XL500, GSX750ES, CB750SC, VT750, ST1300A...took a while...2012 Tiger 1050SE

#6

Offline Rexani

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Re: Ignition switch wiring failure
Reply #6 on: 11 September, 2021, 09:02:44 AM
*Originally Posted by Zevk [+]
Fantastic outcome!  :046:

My disconnection was the plastic connector plug, under the air box.

The white wire was intermittently loosing connection inside the plug.

I cleaned up the inside of the connector with wd40 compressed air, then die electric grease, zip tie securing the plug connection, acrylic automotive hot glue over the wires at the connect and zip tied the harness, to the frame, so it doesn’t move as much

If this happens again, I have posi locks connectors I can use with short jumper wires, or I will just solder the connection permanently if it happens again, as the only reason to disconnect is if replacing the ignition switch. 

For such a critical component, triumph should have spent a few extra dollars and made the harness of better quality ie thicker and longer wires and heavy duty plug connector imho of course… :192:

Yeah, my problem with Triumph is that they don't supply the lower part of the ignition switch with the loom / just the loom separately. There is not a single reason someone has to change all their locks just because the lower part/the wiring failed.

A part that should only cost max 50 euro, and is easily replaced. (Well except for the security bolts but w/e). I'm kind of disappointed really. Would've went for the new part any day of the week if it was available.

#7

Offline Sticky

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Re: Ignition switch wiring failure
Reply #7 on: 11 September, 2021, 10:35:07 PM
Guy's.  This is the type of work that will keep this forum alive. 
Rexani fantastic work, I know it takes work to document with pictures then do the post takes twice the work of the actual project.
 So thank you very much taking the time to share your work. Not sure what your day job is, but you have talent many repair shops don't have.  :037:

I added this to the sticky thread.  Since I don't check the sport stuff much PM Indytiger1050 I try and stop in weekly.

#8

Offline Rexani

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Re: Ignition switch wiring failure
Reply #8 on: 12 September, 2021, 02:01:29 AM
Hey! It actually is a pre- sport model.
I’m a web developer but studied electro mechanics during high school so had a little electrical experience. Most of my mechanic experience I have came from owning a shitty Kia Rio which kept breaking down and due to being a student I didn’t have the money to let it get fixed, so tons of youtube and googling later, it is now something I love doing :)

#9

Offline indytiger1050

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Re: Ignition switch wiring failure
Reply #9 on: 12 September, 2021, 02:10:50 AM
Makes sense and it shows from SE on we lost out and have no idea. If I don't see it, makes it harder to keep straight not to mention a couple changes since. 

I'll leave it as is.  The model difference should be negligible. 
Support the forum.   :031: