Sticky this.

Yamaha has wrapped the wire harness for the instrument cluster around a sharp metal edge in the "crotch" of the fairing stay. It is retained with a plastic tie strap. Pull your windscreen and look straight down between the low beam headlight housings and you'll see what I'm talking about. Mine rubbed through and started popping the ignition fuse at random. It seemed temperature sensitive and defied the wiggle test. It was not water-sensitive. Bumps did not give it away. It only happened on hot days in heavy traffic.

Imagine riding along in the middle lane of a 5-lane freeway with a loaded tractor-trailer rig on your ass and the bike suddenly shuts off with no warning and won't restart. And you've got no brake lights or turn signals. And your left hand holding the clutch in is the only thing keeping you out from under the tractor's front bumper so at best you can only signal with your right hand.

Or on the track banked over to the edge of the tire in a corner at 160 mph with all your weight forward because you've got the throttle pinned and the bike suddenly shuts off and throws all your weight onto the front tire and you low-side into a concrete wall.

I traced and repaired the damaged tan-ish colored wire in the harness, re-wrapped it, and reinstalled it with the OEM plastic tie-wrap. I cut about a 3/4" long section of 5/16" fuel hose and slipped it over the sharp metal edge before tightening it back down so it can't happen again.

I'd recommend that you fix your bikes before you become a road stain.

I'll try to up-load some pics.

See the damaged wiring and the lighter color on the right side of the crotch of the fairing stay where it was arcing out on the sharp metal edge.

5/16" fuel line split to install over sharp metal edge to prevent repeat failures.

Looking up under the nose of the bike. I pulled the wiring down to open up the harness to do the repair. The tan wire was pretty frayed from 5500 miles of this.

The repaired harness.

Looking from the top down again, after poking the wire harness back up between the headlights and re-connecting it. By the way, this costs nothing, and the only tool this repair requires is a phillips screwdriver to pull the windscreen and the two black plastic panels under the nose, so there's no excuse for not insulating yours BEFORE something bad happens. I'm letting Yamaha know about this. Maybe they'll recall the bikes and do something about it.

Hi Many Thanks for your Alert and YES i will check mine as soon as possible .....:thumbup

Thanks for the info... will look into it... :thumbup

someone should write about this to Yamaha, no?

Thanks. I will remember this one later this year when I'll get my 04.

Excellent heads up. Good work!!
:thumbup :thumbup

Good looking out for the 04 owners :thumbup

Right Ok UPDATE :-

I went straight to my garage now as I will be using the bike tomorrow morning and dismantled the wind shield ......


Looked for it and saw that no damage yet happened to mine as she only got 390 km..... Lucky me and thanks to this forum and our bro KirkP who saved mine with his thread.

Took pics of mine but i think no need for upload as his looks fine.

I did rapped special rubber tape which is used even under water around the sharp bracket and re installed the OEM plastic tie-wrap back but this time did not tightened it too much there is no need.


Again Many thanks for your Alert and info ..


:thumbup :thumbup :thumbup

Damn

Good find kirkp

way to lookout.

Thanks I just checked mine and I could see it starting to happen...............................so THANKS

thanks man - this info will save lives

Thanks Kirk, I know what I'm doin later on tonight!

I was racing a 1/4 milloin dollar boat when a $.03 ring failed and the 70'+ carbon fiber mast came tumbling down on our heads......

Thanks

Thanks :thumbup

nice work there dude,thanks for the info,will check it out asap.:thumbup

I will be checking mine tomorrow morning when I'll be detailing the bike. Thanks for posting this important information and I hope Yamaha "Gets the memo"---this is a little more important than TPS reports.

-Jeff Nation
Frisco, TX

Thanks Krikp,

I can see how this will be a problem. I just fixed mine the same way.

Thanks for the info. I'll look at mine tonight and report back.

Mine seems to have zero problems.

Wow, look how spotless.:D

i just checked mine, definately a problem in the making. This is something that needs to be checked, and it is very easy to fix.

Thanks for the info. Mine was starting to tear through the electrical tape but just to the left of where yours was. It wasn't rubbing on that middle round piece of metal. It was below and to the left. There is a sharp corner that mine was resting on and started to break though. So I used another zip tie and pulled the wiring away from it .

Appreciate the info...

My bike being so new is undamaged, but the zip tie was so tight that I could see a future problem without a doubt.

All I did was loosen the zip tie as they had it cranked down for some reason, hell I dont even think the zip tie needs to be there at all.

Thanks, easy work, big problem saved..............


:thumbup :thumbup

Way to go Kirk. Good catch. Just checked mine. Zero wear so far. thank goodness.

i used 100mph tape on the bracket, and i'm in w/ shnapper, i didn't put the zip tie back on. can't wear out from what it doesn't touch.

My bike is serial #429. I checked the wiring harness. There is no wear at all. I've got about 4,500 miles on the bike. My zip tie is very loose and the harness does not come in contact with the sharp metal edge.

Thanks for bringing this to my attention. If the zip tie is too tight, I can see where this would cause a big problem...

jack

this should be a sticky...

Thanks KirkP! I'm checking!!!

Hey KirkP, thanks for the info... No problems visable yet, but it never hurts to take preventative measures.

good looking out kirkp. I'll pass this info along to any '04 R1's i meet along the way. Thanx for the info. :rock

Your worst case scenario is exactly what happend when a rectifier let go...it happend to me once in the right lane of a highway with Ms.Minivan who didnt had a clue why I suddenly dropped speed...and was tailgating me like there was a nuclear blast behind us.

Originally posted by r1-superstar
Wow, look how spotless.:D

:lol Ya hardly ever ride the thing bro! :2bitchsla

































































j/k:bow

Originally posted by COLDSTONE1300
good looking out kirkp. I'll pass this info along to any '04 R1's i meet along the way. Thanx for the info. :rock

:iamwithst I'll pass it on to the guys two guys I know with 04R1's. Performing surgery on mine as soon as I've finished reading the mail.

Cheers and a great safety pick-up. Well done.

Warp :thumbup

I checked mine this morning. There was no wear on the black tape or wires underneath. But I did add a bit of plastic wire tube around the wires at the point where it touches the metal part as a precaution. Thanks for the warning.

Originally posted by XXXMAX
Thanks Kirk, I know what I'm doin later on tonight!

I was racing a 1/4 milloin dollar boat when a $.03 ring failed and the 70'+ carbon fiber mast came tumbling down on our heads......

Thanks

You racing a Farr, Tartan, or what? Carbon fiber mast probably cost more than the boat......LOL I hope it didn't tear out all of the stays. Ouch.

Originally posted by downtown
Thanks. I will remember this one later this year when I'll get my 04.






:iamwithst Same here Thanks :thumbup

Did mine before my ride today. There was no damage but I did it anyway. For those that have not done it yet you may want to try my way of repair. I am an Electrical Contractor so I took some Rubber tape (used for insulating Large wire makeup) and wrapped it a couple of times. Then took some "3M Super 33" electrical tape (one wrap is good for 600 volts) and wrapped it a couple of times. It looks very pro and will never wear threw. Both these products can be bought at any wholesale house or even a Home Depot. Thanks Kirk.

Thanks for the heads up. I checked mine and didn't see any problem but I did do some preventative maint. Instead of wrapping the wire, I cut a small piece of rubber edging (came with the Puig windscreen) and slipped it over the sharp edge. I've got to imagine you could use door edge guards the same way.

Just another suggestion. Again, thanks for lookin' out!

-Moto

Originally posted by MotoFanatic
Thanks for the heads up. I checked mine and didn't see any problem but I did do some preventative maint. Instead of wrapping the wire, I cut a small piece of rubber edging (came with the Puig windscreen) and slipped it over the sharp edge. I've got to imagine you could use door edge guards the same way.

Just another suggestion. Again, thanks for lookin' out!

-Moto
Excellent tip. Gonna check check mine right away. This forum is the best.

Originally posted by harrier
Way to go Kirk. Good catch. Just checked mine. Zero wear so far. thank goodness.

i used 100mph tape on the bracket, and i'm in w/ shnapper, i didn't put the zip tie back on. can't wear out from what it doesn't touch.

Hey man, I did put the zip tie back on :lol :lol But I left it way loose just to act as a catch ring instead of a friction producing wire killing ring.......

Just lettin ya know.............:thumbup



:fork

Originally posted by Diamond
Did mine before my ride today. There was no damage but I did it anyway. For those that have not done it yet you may want to try my way of repair. I am an Electrical Contractor so I took some Rubber tape (used for insulating Large wire makeup) and wrapped it a couple of times. Then took some "3M Super 33" electrical tape (one wrap is good for 600 volts) and wrapped it a couple of times. It looks very pro and will never wear threw. Both these products can be bought at any wholesale house or even a Home Depot. Thanks Kirk.


Dude your scaring me....... :scared

It's not razor blade sharp, just loosen the fricken zip tie and be done.

:fork

Originally posted by Shnapper
Dude your scaring me....... :scared

It's not razor blade sharp, just loosen the fricken zip tie and be done.

:fork

LMAO! Yeah I know and to be honest there was no wear on mine at all but since I was taking up valuable riding time this morning I figured I would do it right.

:yesnod I fixed mine. I have 3200 miles om mine and it wasn't through...yet. I duct taped in and put a couple of zip ties on it.
Good lookin out bro:corn

I just came in from checking mine....I have 1700 miles on mine and it was wearing just like I saw in the pics.....not through the tape yet but there was some definate wearing!! Fixed it with another round of tape and the tubing on the metal. Thanks man....have one on me!! :beer :beer

Checked mine out today & no problems at all..almost 3000 miles. The zip tie is pretty loose though so maybe thats the problem of the tie is too tight?

Just to be real clear- the problem is NOT the tightness of the tie-wrap. The wire harness was not punctured from being pinched. It had abraded through into the wiring. That abrasion came from movement that was allowed by the looseness of the tie wrap. The real problem is exactly what I said- Yamaha wrapped the wire harness around an unprotected sharp metal edge.

He's right about these wires, I crashed a little while back and it cut all of these wires in half.

Originally posted by KirkP
Just to be real clear- the problem is NOT the tightness of the tie-wrap. The wire harness was not punctured from being pinched. It had abraded through into the wiring. That abrasion came from movement that was allowed by the looseness of the tie wrap. The real problem is exactly what I said- Yamaha wrapped the wire harness around an unprotected sharp metal edge.

Well since were entering the "exact zone" Maybe my harness isn't or wasn't routed like yours. Mine does not wrap around that bracket it merely sits in front of the bracket, I wonder if yours was routed a little different? I looked at your pics again and the size of the blemish in the harness before repair. Was your harness contacting that bracket towards the bottom where that round dowel in the center sits?

Do you have a pic of the routing before you even started to pull the harness for repair so I can see exactly how your wiring was contacting the bracket?

saw that as well when installing the shit bodywork from hotbodies, went ahd and relocated the wiring, good show. thanks,,,

thanks man!!!

Didn't see any damage...figured i got the windshield out so might as well do some preventative measures. Sure 'nuf couldn't find any electrical tape....so i just did some wire re-arrangement. Placed the two blue plastic connectors between the 'wire' and the metal to protect it.

;)

Thanks for the tip "KirkP"!
Yesterday I removed my windscreen to install my new dark smoke Puig and because of your tip, I corrected the problem you pointed out. Mine hadn't yet cut through the tape but I could see that the harness had a hard rub and indentation. I cut the tie strap and reinstalled another pulling in the opposite direction, holding the harness away from the metal saddle. I attached the strap around a plastic mounting bracket at the farthest point near the headlight assembly and just rapped it around the harness and then back again. No question about it, this was an electrical short waiting to happen. Yamaha need to address this with a service bulletin to all 04 R1 and maybe R6 owners ASAP! Thanks again!

RIght on - this site is the shit*%^ shoulda had the internet 50 years ago!!! Ride on!

Thanks Kirk!!!

I'll be checking mine tonight.

I agree this should become sticky!

TTT

Ive had my bike apart 3 times and havent seen any of this CRAP of wiring routing. U guys that dont know what to do, Dont worry this thread and the ones ive read on this same topic is :bs :beer :beer

Uh..... Wheatman, you might want to take another look, but do it before 8:00 PM, your eye sight might be a little better; otherwise just ignore it and take your chances, but it's definitely not crap! I located the wire bundle hard rub condition within minutes of looking for it. Depending on the circumstances it might take years to wear through, on the other hand it might fry your wiring system when you’re least expecting.
As a Flight Line mechanic at Boeing, we look for wiring conditions exactly like this one, and this would NEVER FLY! Again Kirk, thanks for the good eye!!!

Thnx for the tip:thumbup

Kirk is the ultimate, it takes someone elses blown fuses to help us with ours. I will check it this weekend. :snorkel

Checked mine out and had no wear but I can see where it could start. Left the tie wrap off and put some rubber sealant on the edge of the metal. Should be good to go.

Great Find!!

thanks kirk!!!!!!!

:thumbup Thanks.

hay Kirk! good find bro! i got an 03 but i'll still check it jus in case.

Good job :thumbup

KIRK, Yamaha needs to pay you for this. You just saved them some lawsuits.

Originally posted by Soulja
KIRK, Yamaha needs to pay you for this. You just saved them some lawsuits.

:iamwithst Yamaha needs a :2bitchsla to make 'em realise the potential disaster possible, in a worst case scenario on the 04R1.

Thanks for the tip and good looking out man:thumbup

So what you are saying is, beware race tracks with concrete walls sitting right next to the track...

You're welcome guys. I couldn't beleive that any Japanese manufacturer would ship something like that. By the way, I called Yamaha- I pointed out that somebody could get killed, and they could not have cared less.

bump

Just fixed mine I could not find this tread when I needed it but it was blowing my tripmeter fuse I taped it flexed loomed it then taped it again then put flex loom between the metal and wire should'nt be a problem again. I had one Yamaha dealership tell me it was my alarm I new he was full of it because I had to get my boots on.:yesnod

just pulled the screen from my 04, and yep i checked it just in time, it had just cut through the wrappings and i can see the wiring loom.. thanks heaps for this tip 8000km

is this problem found also on the 05? my bike is manuafactured 01/05

anyone check 05s? i'll check mine just in case

pulling the screen is easy as, i would make the mod just for the sake of it. I cut a thin piece of plastic out of a water bottle and wrapped it around the metal cross piece where the loom is pulled against bare metal

:thumbup

great looking out. Thanks.

Originally posted by AmpliFyre
is this problem found also on the 05? my bike is manuafactured 01/05 Yes mine is 05 also about that same year of make.

Cheers mate, will take a look at mine

Steve

Thanks for the warning! I checked my '04 R1 and there wasn't a problem (yet), but I could definitely see the potential.

Also, the '05 R1 has the same wiring setup, so those owners of the '05 should check their bikes as well. I'm sure the '06s will look identical, so every R1 owner needs to make sure this gets corrected.

Again, thanks KirkP for telling everyone about this. That's the best use of this forum I've seen so far!

Originally posted by KirkP
Sticky this.



I agree.

Kirkp. thanks alot. :thumbup

Just checked my '05 R1 (build date: 5/2005), and it's obvious that Yamaha hasn't done a damn thing to correct this...

Arrow points to harness contact:


http://www.fjrtech.com/photos/r1/WireHarnessChaff.jpg


It's kinda hard to see in the photo, but yellow arrow points to where the metal brace has just begun to cut into the harness:

http://www.fjrtech.com/photos/r1/WireHarnessChaff2.jpg


As opthers have mentioned, thanks for looking out, Kirk!

Prolly outgha edit the title of this thread to include both '04-'05 models, as Yamaha obviously isn't doing DICK to correct this problem... :mad:

Just did mine finally, was showing a very light abrasion, btw its 05 with 3k miles. I used garden hose, perfect fit, wrapped with electrical tape. Thanks for letting everyone know.

i have just returned home after checking my bike at work in the workshop .
sure enough when i removed the screen i could see the problem straight away . when i disconected the conectors and pulled the harness down i found that it had rubbed through the insulation tape and was rubbing through the insulation on three wires in several places .
i have re insulated the harness again and cable tied some silicone hose in place on the offending bracket .
i also found very heavy corrosion in the two blue connectors so i cleaned these and squirted some white grease in to stop any further corrosion .
my bike is used every day in all weathers and has done 13,787 miles .and is a 04 puchased on 1st of march .
i will in form my local dealership to see if they are aware of the problem .

top marks for finding and reporting of this very serious fault .

Thx for the heads up. My bike has 75 miles on it took the windscreen off what do you know. You can see where it will rub through...Thank you......Build date 05/ 05

Here's a pic

This is also true for the 2003, i just took my bike apart for some custom paint and frame polish and found the same situation. i had just taken some electrical tape and sealed it back up. Luckily mine had not rubbed all the way through to the wires yet, but if i had let it go any longer it would have surely rubbed through!!:fork

I pulled my windscreen the other night to check. The edge of the bracket is just starting to dig into the wrapping but no metal-to-metal contact yet. I plan to rectify this this coming weekend.

Hi and thanks ,just been to the workshop and checked and its rubbing('04) ,carried out the repair .,
Thanks again
John

good tip road racer thanks for the heads up. I checked mine out but found nothing out of place on my 05' i have about 15,000+ miles. I have the raven and i wondering if its only a fault on the blue r1s? Thanks again man

I have 2900 miles, just checked mine...it wasn't rubbing through, but I did take that tie off and pulled it away from the bracket

Thank for the info.

Guys let me ask is the 04 R1 most problem bike ?

:eek: Holly crap guys, im checking mine tonight when i get home, my lights have started switching off for no reason then they just come back on again with a little tap.
Thanks for the heads up :thumbup

Originally posted by galatyali
Guys let me ask is the 04 R1 most problem bike ?

Well, it's the 04, 05 and maybe 06...

You hear of more 04's since they've been around the longest and had 1 or 2 more years of rubbing. But honestly, I had 3000 miles on my 04 and I had no signs of rubbing yet, but I took the zip tie off, and moved the cable just incase.

Did mine. No wear was apparent but did it anyways. Thanks. Great catch.

Hey guys for what it's worth.... I actually found this forum by searching for a fix to a problem I was having... Every time I accelerated hard my headlights blow a fuse and stop working.
After replacing the fuse and repeatedly blowing it a few times I was really frustrated and couldn't figure out what the heck was happening! Well, I saw this thread today and the first thing I did was go outside and pull my windsheild, and What do ya know! The front stay had worn through black tape and the rubber coating of the main red wire for my headlights, at exactly the spot you guys were talking about. Everytime I would hit the throttle hard, or hit a fairly large bump, it was grounding out that wire and blowing the fuse.

Fortunately this started happening to me on a day ride, but you can imaging how fun it would be to lose all of your lights on a windy back road in the dark.

Thanks a MILLION for the tip! I would probably be still outside scratching my head if I hadn't read this!!

-Rob

Glad I could help. This is one of those one-in-a-million things that once someone found the fix for it, it wouldn't have been right not to share it with those that could be helped by it.

Yamaha should fix this.

They should but it's a relatively simple fix (unless it's already messed up). Yamaha is really screwing up with these types of issues. This and the TPS issue are very life threatening if they become too extreme. Too bad no one cares about us riders :(

I was having my neutral light flickering on and off intermittently on my 04 R1.
I took it back to the dealers a year ago and they replaced the neutral switch and relay. I have had this done two more times since, but the problem still persisted.
After reading this thread I checked the wire loom and sure enough the metal bracket had chaffed through the neutral switch wire and was shorting on the bracket. A quick repair with electrical tape and a plastic hose fitted over the wires so it won't happen again and the fault has gone.
I phoned my dealer to let him know what the fault was, and he had never heard of it. He told me he then phoned Yamaha UK how also stated they had never heard of this fault and my bike was the only one they had ever come across.

thanks for posting this, dude! going to fix mine...

Thanks for sharing on what may become a more major undertaking out of something that is otherwise easily curable. I was having some TPS type stalling issues, that I figured I better check this too... but it was perfectly fine thus far. Like the rest... I did some preventative maintanence by inserting a piece of self adhesive automotive foam along the harness where it meets the fairing stay edge. Very easy to stuff it in between, and appears will work very well... probably easier than wrapping tape around the problem area.

Thanks again as we never wouldve found something like this until there is actually a problem.

Rob

THANKS FOR THE INFO

I don't want to seem like I'm lazy or anything, but would someone be able to look at my pic and let me know if they think I'll be immune to the problem? I don't want to have to cut all the zip ties that I have strategically placed to hold down my radar detector to look under it to see if it's rubbing. I cut the stock zip tie and pushed that harness out of the way to make room for my detector, so I don't think it is still over that sharp section of the stay. I don't remember off hand how far down it was though. If anyone could just take a glimpse of the pic and say yay or nay, that would be great.

I don't want to seem like I'm lazy or anything, but would someone be able to look at my pic and let me know if they think I'll be immune to the problem? I don't want to have to cut all the zip ties that I have strategically placed to hold down my radar detector to look under it to see if it's rubbing. I cut the stock zip tie and pushed that harness out of the way to make room for my detector, so I don't think it is still over that sharp section of the stay. I don't remember off hand how far down it was though. If anyone could just take a glimpse of the pic and say yay or nay, that would be great.

It looks like you moved the harness. I might be wrong it has been a while since I have done mine. If anybody else wants to chime in please do.

It looks like you moved the harness. I might be wrong it has been a while since I have done mine. If anybody else wants to chime in please do.

Yeah, I did move it as far as it would go without putting too much strain on the plug, but I was just wondering if it looks like it has been moved enough.

Yeah, I did move it as far as it would go without putting too much strain on the plug, but I was just wondering if it looks like it has been moved enough.


Yes IMO it has been moved enough if you don't feel right about it put some flex loom over it and tape it up some more.:riding

i' m having trouble with my fuel light ? maybe this is the problem ? thanks

thx for the info matey. I also have suffered this problem but mine had rubbed through a different cable causing the dash to forget the time and shift light settings. Could of been a whole lot worse i guess!! I read this a while ago and didnt bother looking untill i had the problem. So today i have repaired the cable and all is well again. I cut the Cable tie which is half the problem and made sure it wont happen again. Once again thankyou for posting this info on here.
Chris

thx for the info matey. I also have suffered this problem but mine had rubbed through a different cable causing the dash to forget the time and shift light settings. Could of been a whole lot worse i guess!! I read this a while ago and didnt bother looking untill i had the problem. So today i have repaired the cable and all is well again. I cut the Cable tie which is half the problem and made sure it wont happen again. Once again thankyou for posting this info on here.
Chris

Same thing here.:scared

Damn thanks for this guys, I'm definitely going to pull my windscreen now and check that before riding season starts, that would suck bad to have the bike cut out mid corner.

subscribed!!!

Every time i turn my ignition on i aways blow my 25 amp fuse for the headlights. I have taken the windscreen off and checked all the wires around the metal bracket to see if any of them would be rubbing on the bracket. But i couldn't spot any problems with the wires. Is there something i am missing?

ok checked and remedied the problem but my headlights still won't come on. Checked bulbs, checked fuse, and checked the harness. Still a problem. HELP!!

Can only be from the front harness/relays or the switch

sucks I use my one to commute. Can't get her in to the dealer till next friday. Anyone know of a quick fix? Tried riding but felt like the cagers really didn't see me. Corner lamps work but head lights still can't figure them out?

sum it up harness blown from water damage. Y.E.S covered it to replace. Will be getting it back in 2 weeks. Aaarggghhh!!

f%&*@ harness back ordered until may...when it rains it poors!!!

Never really noticed this thread till Kangaroo just linked it on another post. Thanks!!!

Just looked at my 06, and what do you know! That bracket was digging into the harness. I just thru some wire loom on there. Had to trim the bottom of the wire loom, So it would slide over the T part of the harness.

I had ran my lap timer cable right thru that same place, feel stupid for not noticing it then..........:)

Do you think this could be the reason I have to slap my right side fairing every once in a while to get my headlights to come on? I cant narrow it down...Any idea of places to check?

Never really noticed this thread till Kangaroo just linked it on another post. Thanks!!!

Just looked at my 06, and what do you know! That bracket was digging into the harness. I just thru some wire loom on there. Had to trim the bottom of the wire loom, So it would slide over the T part of the harness.

I had ran my lap timer cable right thru that same place, feel stupid for not noticing it then..........:)




Happy to help, man.

Mine started doing it pretty soon after I bought it, and I was afraid to take it on track until I had it nailed down.

http://www.ourchurch-graphics.com/member/p/pylandracing/turn3.jpg

http://http://www.ourchurch-graphics.com/member/p/pylandracing/turn3.jpg

just went out and looked at my 06 and they must have fixed the problem on mine cuz the wire harness was about 1 1/2 inches away from the fairing stay and there wasnt even a wire tie. i did notice that my wire loom comes from under the right (brake side) headlight. no cuts or anything. thanks for the info tho...could have saved lives!

just went out and looked at my 06 and they must have fixed the problem on mine cuz the wire harness was about 1 1/2 inches away from the fairing stay and there wasnt even a wire tie. i did notice that my wire loom comes from under the right (brake side) headlight. no cuts or anything. thanks for the info tho...could have saved lives!

I've had the front all pulled apart before and didn't pay attention. I also haven't seen this thread until now. Hopefully mines the same as yours since it's an 06 also. Either way, I'll check it it eventually.

Did this today. I used an old rubber brake line guide and some electrical tape. Mine wasn't rubbed through at all but I like the extra insurance. Thanks for the thread. :thumbup

thanx 4 the great info...just got my 04 3 dayz ago!

Well since were entering the "exact zone" Maybe my harness isn't or wasn't routed like yours. Mine does not wrap around that bracket it merely sits in front of the bracket, I wonder if yours was routed a little different? I looked at your pics again and the size of the blemish in the harness before repair. Was your harness contacting that bracket towards the bottom where that round dowel in the center sits?

Do you have a pic of the routing before you even started to pull the harness for repair so I can see exactly how your wiring was contacting the bracket?

I was working on my '06 yesterday and decided to move the harness through the hole above it for cleaner routing and then noticed that edge. Happened to come across this thread now and I'm confused why no one seems interested in your (our) method. I think Yamaha just misrouted the harness because the part I have it going through now appears designed to facilitate the harness in such a way to avoid any chafing or cutting.

Thanks for the info, im gonna check my 05 today..

New Years day (1-1-11) and I finally have a day off to check mine.
Mine is an '06 and it did not have any problems.
The black tape around the loom did not have abrasion marks.
But I see where it could become a problem.
The wire loom on mine was hitting right against the metal area.
So I took the preventative measure of placing a rubber sleeve
aournd the metal area and tightened the zip tie back up.
Everything is good to go.
I suggest everyone do this.
Sorry about your bad luck KirkP. Thanks for sharing though brother.

EDIT (1-2-11): By the way my '06 was manufactured 06/'06
I doubt any changes were made from the '04 to '06 model years regarding this loom.
Also I would not route the loom behind and through the opening at the fairing stay bracket, because there is very little room for clearance when you move the steering from full left or full right from another bracket and brake lines. Keep the loom routed below and in front of the metal fairing stay bracket ( just as delivered in stock form ) and place a rubber sleeve like I have done around the fairing stay bracket and put the harness loom zip tie back on to keep it all in place.

NOTE: Even with the rubber sleeve that I installed there is very little clearance when turning the steering from full left to full right with out hitting the brake lines and a plastic bracket. The plastic bracket is item #16 (strg cover, assy) It's located under "Steering" on the Yamaha parts fiche. If you go out to your R1 and look (looking down from the top of your triple tree) at your fairing bracket and turn your steering from full left to right you will see this plastic braket that I am talking about.

You will see it in my pic (#4). That is the plastic bracket, it has a small yellow mark on it.

You can also see my after market Galfer brake lines come close to this area (pic #5).
I did not install the Galfer 3 piece brake line kit for use with the stock Yamaha spliter for my front brake lines. So I cut rubber vacuum line sleeves and zip tied them to my 2 piece Galfer brake line kit to protect the brake lines from abrasion where the stock Yamaha spliter use to be bolted to (which is also metal). I learned this valuable set-up from some one else on this forum also. So I can't take credit for it.

Thamks mate a good find as ive jusct checked mine and noticed it has started to hsppen so thankyou....... Any more tips please do not hesitate to let me/us know, thanks again ;-)

Just looked on my 8000mile 04 R1.
Signs it may be starting, zip tie medium tight - you wouldn't notice if you weren't looking though, I'll find something to wrap around bits.

Thanks, excellent thread!

Peteturbo.

Sorry to resurrect, but my buddy has an '04 R1, I read this thread and we checked his, was nearly toast! Great post man, may have saved my bro's ass!