Read This- Critical Safety Issue On '04 R1:

drunknchi · 04-02-2007, 07:06 PM

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!!

martinc · 04-03-2007, 03:41 AM

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

drunknchi · 04-04-2007, 03:09 AM

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?

drunknchi · 04-11-2007, 02:50 AM

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

drunknchi · 04-17-2007, 03:13 PM

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

MotoGPracing · 01-13-2008, 03:19 PM

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..........

Bike Medic · 01-23-2008, 12:11 AM

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?

KirkP · 05-31-2008, 02:54 AM

Quote:

Originally Posted by MotoGPracing

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.

chmurman · 05-23-2009, 05:58 AM

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!

easbaysav · 06-16-2009, 02:58 PM

Quote:

Originally Posted by chmurman

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.

SAB · 07-03-2010, 08:44 PM

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.

icy0069 · 08-04-2010, 07:56 PM

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

brokened · 09-12-2010, 08:37 PM

Quote:

Originally Posted by Shnapper

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.

Abz · 12-14-2010, 06:33 AM

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

R1Jamn · 01-01-2011, 10:20 AM

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.

Glen · 01-10-2011, 01:05 PM

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 ;-)

peteturbo · 07-10-2011, 02:53 AM

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.

K5ShiftRed · 04-07-2013, 01:25 AM

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!