The problem:
Bike repeatedly cuts out while riding, regardless of rpm. The tach needle goes to 0, HESD light comes on, MIL comes on, but all other power (headlights, gauge lighting, etc) stay on. This happens briefly, maybe just a second or 2, and then it will run normally, tach will resume, HESD and MIL lights go out. Its very intermittent, will happen over and over for about 10-15 seconds or so, then run fun for another 20 minutes. Sometime it wont do it for hours, then it'll start doing it. Also noticed sometimes when I turn the key on I don't hear the usual noise which I assume is the fuel pump priming. If I jiggle around the fuse box sometimes it seems to help, but that could just be dumb luck. Also, when I jiggle it around, it doesn't cause the fuel pump to prime, I have to turn the key or engine switch off and back on to see if it worked.
What I've done:
It seems to be an obvious electrical issue, but with what component? Battery is new and terminals are tight. Followed the power wire from the battery as far as I could, connections are tight and clean at the main fuse, etc. Followed the ground wire, same deal. Checked the grounding point under the tank, its tight and corrosion free. Tried pulling the MIL code, jumpered the brown and green wires on the service port (DLC), but the MIL light stays on solid and never blinks when I turn the key on. Pulled the fuse box off and checked the underside of it, all connectors seem to be properly seated and making good contact, no corrosion or melted wiring or plastic from possible arcing. Removed the fuel tank to pull out the fuel pump and check everything, all connectors seemed tight when I removed them.
Also, I never have to restart the bike when it cuts out. If I maintain throttle, it comes back on and operates normally until it cuts out again.
Any ideas of what else to check or possible causes? Thank in advance for any advice everyone.
Bike repeatedly cuts out while riding, regardless of rpm. The tach needle goes to 0, HESD light comes on, MIL comes on, but all other power (headlights, gauge lighting, etc) stay on. This happens briefly, maybe just a second or 2, and then it will run normally, tach will resume, HESD and MIL lights go out. Its very intermittent, will happen over and over for about 10-15 seconds or so, then run fun for another 20 minutes. Sometime it wont do it for hours, then it'll start doing it. Also noticed sometimes when I turn the key on I don't hear the usual noise which I assume is the fuel pump priming. If I jiggle around the fuse box sometimes it seems to help, but that could just be dumb luck. Also, when I jiggle it around, it doesn't cause the fuel pump to prime, I have to turn the key or engine switch off and back on to see if it worked.
What I've done:
It seems to be an obvious electrical issue, but with what component? Battery is new and terminals are tight. Followed the power wire from the battery as far as I could, connections are tight and clean at the main fuse, etc. Followed the ground wire, same deal. Checked the grounding point under the tank, its tight and corrosion free. Tried pulling the MIL code, jumpered the brown and green wires on the service port (DLC), but the MIL light stays on solid and never blinks when I turn the key on. Pulled the fuse box off and checked the underside of it, all connectors seem to be properly seated and making good contact, no corrosion or melted wiring or plastic from possible arcing. Removed the fuel tank to pull out the fuel pump and check everything, all connectors seemed tight when I removed them.
Also, I never have to restart the bike when it cuts out. If I maintain throttle, it comes back on and operates normally until it cuts out again.
Any ideas of what else to check or possible causes? Thank in advance for any advice everyone.