Service Manual wiring diagram errors.

couchrocket3

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Nov 2, 2008
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Williams, AZ
HEY! Any wire-heads out there?
I've been troubleshooting electrical problems with my bone stock '05 R3. Basic problem is ignition circuit related-(no start - although the starter, fuse & relay are good....trust me, they are).

Using my Triumph Service Manual (issue 1, 05.2004), and chasing error codes (from my TuneECU), I started pinpoint testing the Crankshaft Sensor connections.
I know, this sensor does not disable the ignition circuit, but it was the first simple sensor I could test to eliminate the TuneECU error code.

According to my precious service manual, the ECM is connected to the sensor through pin numbers A14 and A13. What could be more simple - right?

Well, here is what I found after following the logical tests (found on page 11.60/61 in my book):
1. Cable integrity is visibly OK;
2. There is no short circuit on either pin
3. Continuity is good on Pin A14 (through the wiring harness to the sensor connector at pin 1).

HOWEVER, when I tried to put probes into the socket for A13 I discovered that there is no wire or socket inserted into the A13 connecor port!
Not only that, but there is a factory installed white plastic dust plug in the A13 port - proving (to me) that A13 was never used to connect the ECM to this sensor!

I could go into more excruciating detail about this (with photos etc), but I simply wanted to find out if anyone out there in Rocketland has ever run into THIS problem.
Also, if this circuit diagram is wrong, how many others will I find?

NOTE: The wiring loom is original to the bike.

Am I working with the wrong Service Manual?

ANY ADVICE IS DEEPLY APPRECIATED.
 
If you have a bone-stock 05 Rocket and haven't fitted a headlight relay kit, then you have most likely fried the ignition switch. A well known weakness in the pre-10 models.
 
Thanks for the interesting feedback.
First - I've been searching this site for years and never ran across a "well known" fix for a headlight/ignition switch weakness.
Can you clue me in on how a relay kit will solve the original issue I posed in my post? (IE - a misleading wiring diagram).

Second - There is nothing wrong with my ignition switch (it inputs and outputs exactly as it should).
I get it, the power draw of headlights could compromise ignition, but the headlights always turn off when the starter switch is pressed.
Also, when I pull the fuse on the headlights and try to start, there is no change to the problem.
I'm beginning to be concerned that the ECM is failed, since all the sensor permissives and relay check out.

Got any other ideas?
 
Search Eastern Beaver for interesting reading on the headlight relay fix, going back many years
 
There's various contributing factors to the ignition switch failures on the early models. First, the wiring to the ignition switch is somewhat tight and always under stress, particularly when the handlebars are turned. Second, the headlight circuit is routed entirely through the ignition switch so 2x 55W of energy to light the headlights is going through a wiring connection that is held in place by a solder weld. Yes, the starter relay cuts the power to the headlights during the starting process but the main load still remains after the engine is running.

The headlight relay kit relieves the load on the ignition switch circuit. Another big benefit is significantly brighter headlights. It really is noticeable.

Now back to your situation. Yours may not be the ignition switch if the headlights come on and the gauges sweep when the key is turned on.

Another thought is have you checked the grounding circuit? or do you have an alarm system? The negative battery cable can corrode on both ends (btw, there is another recommended mod for the negative battery cable).
 
I'd recommend you check the ignition switch barrel for a loose or burned connection. There was a sticky on that in the How To forum some time ago. Good luck.

FYI I installed the Eastern Beaver kit in 2007(ish) and haven't had any ignition issues.
 
If you pull the headlight fuse the bike will not start.

That's probably because the power to the starter goes through the headlight circuit. A relay opens the power to the headlights but the circuit is active. Installing the EB kit bypasses that problem (and you get brighter headlights). I opted for the headlight cutout as well, which allows me to turn the headlights off with the ignition on. Most of the starting problems for the early models was in the ignition barrel due to over heating the solder joints.
 
I am still running with out EB wireing .I did move my ignition switch years ago wen the wire pulled out of it due to a upgrade that left the wireing harness just alittle shorter than original this was done by dealers and factory on the 04/05 models wen you turned the Handel bars you tuged on the harness . Heat was never an issue with mine
 
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