05-23-2020, 09:19 PM
Ok, maybe i should have also told you what his symptoms were just in case your technical German was not up to scratch;
Apart from the faulty generator repair ( Zam did not touch the battery during that time ) the bike started to splutter and the warning light came on, the rider was able to limp it into Zam's workshop with a "check engine" warning light.
That usually means there is a code "set" in the e.c.u. so Zam connected the healtech diagnostic software on his pc with an extended usb cable to the diagnostic connector on the Honda only to find out no code has been set but the battery voltage showed an unusual 13 volts without the engine running which is not possible, so then he went back to basics and did the very important visual inspection.
That is when he found the problem with the battery terminal bolt which was tight but too long for the thread inside the terminal, no amount of electrical testing would have pointed to this fault, it even started the bike many times, the battery and connections must be ok for that to happen, right?
In a previous job we had a Scottish electrical inspector checking all the switchboards we manufactured, one day he walked over to me and said " have a look at this, can you see what's wrong with this connection? "
Initially all looked ok to me until he pulled the cable out of the big crimp lug, it had been perfectly covered in heat-shrink but he spotted something did not look right, the two cables next to it were crimped normally but this one was not..........
He prevented a switchboard fire that day and all electrical tests showed no faults; experience
Apart from the faulty generator repair ( Zam did not touch the battery during that time ) the bike started to splutter and the warning light came on, the rider was able to limp it into Zam's workshop with a "check engine" warning light.
That usually means there is a code "set" in the e.c.u. so Zam connected the healtech diagnostic software on his pc with an extended usb cable to the diagnostic connector on the Honda only to find out no code has been set but the battery voltage showed an unusual 13 volts without the engine running which is not possible, so then he went back to basics and did the very important visual inspection.
That is when he found the problem with the battery terminal bolt which was tight but too long for the thread inside the terminal, no amount of electrical testing would have pointed to this fault, it even started the bike many times, the battery and connections must be ok for that to happen, right?
In a previous job we had a Scottish electrical inspector checking all the switchboards we manufactured, one day he walked over to me and said " have a look at this, can you see what's wrong with this connection? "
Initially all looked ok to me until he pulled the cable out of the big crimp lug, it had been perfectly covered in heat-shrink but he spotted something did not look right, the two cables next to it were crimped normally but this one was not..........
He prevented a switchboard fire that day and all electrical tests showed no faults; experience
