Electric bug

[Django]

Recently the electric of my CBF showed strange behavior. Out of the sudden the indicators didn't work anymore and the fuel consumption indicators worked while running the bike, but refused to show values anymore after the ignition was off.

Well, some research led to a very hidden broken cable right behind the fuse box. The direct power supply (not switched by ignition) was rotten off the fuse box. The red cable, that looks like cut off, belongs into the fuse box.





Now I still wonder, how to repair that. The fuse box is integral part of the cable harness and not replaceable.

Btw. this is my working place in the garage of my new home:

[the Ferret]

popgun can tell you how to fix that. he is an electrical guru

[Lord Popgun]

I would have already maybe made a suggestion, but I can't see the pics at work. Heck I might could repair it. I'll let you know later.

[Django]

"New box" was my first thought, too. However it is not available at Honda.

It holds 6 fuses and a double diode. The socket for the diode is special, that currently keeps me away from replacing the box by some kind of standard fuse box.

The broken cable only feeds the 2 fuses out most right in the box.

[GoldOxide_imp]

Django: Based on the image, the lead and connector port is salvageable. <clean><strip><extend lead><crimp><clean port><insert>

You need to extend or replace the lead because it appears short and stressed.

Also inspect and service neighbouring connections and harness cabling.

The job should take less than 1/2 hour.

[max]

Django it's not clear which model cb you have, i looked at the wiring diagram of a cbf 1000 from 2008 and it appears the wire colors are red 12v supply, red/green instrument panel and more.

So disconnect the battery neg connector or the fuse supplying the red wire when working on the bike.

I would try Goldoxide's suggestion first by removing the corroded connector with a small tool ( spade connectors like these have a small tab that enables them to slide into the fuseholder housing but lock them into their position, you have to dis-engage that clip ) that enables you to slide it out of the fuseholder and solder/lengten the wire.
I would also spray some chain lube into the wiring side of the fuse box to protect the rest of the fuse connectors.



Second option is to buy an inline separate fuseholder and solder that between the red and red/green wire;



Popgun may have suggestion no 3.

[pekingduck]

You can repair the broken connection by crimping a new terminal to it, or by splicing a piece of already-crimped wire to it.

Honda uses hand-crimped terminals in their harnesses, not soldered. It requires a special crimper that rolls a crimp over the plastic insulation, and rolls another crimp that goes over the bare wire. Much better than the normal single-crimp connectors found at auto parts stores. The additional crimp on the insulation acts like a strain relief so much less likely to pull apart.

These terminals have a locking tab that holds them into the multiple connectors, and can be released with a small blade (you can use a paper clip and smash the tip flat with a hammer).
Terminals and crimper tool are available from:
https://cycleterminal.com/

For this repair, I would find an old wire that has the same terminal, cut and splice it. Be sure it has the retaining tab on the bottom side, otherwise the connector will slide out the back. I would clean all the terminals in the connector block and pack di-electric grease into the back (never on the terminals themselves).

[peterbaron]

After your repair, as suggested by few other members, you should "bath" the entire box in dielectric grease, or silicone lubricating compound by Würth or simply in vaseline/petroleum jelly, preventing from further corrosion in the future.
It looks to me like road's salty intrusion.

Optional: If you could send a pic of this box/joint front & back, I may take a look to see if I have it (with wires & connectors) and if it could be adopted as a permanent replacement. I also would like to see pics of fuses and relays that go in....everything separately, so I can make fitting judgement. Up to you.

[Django]

Thanks a lot for all the good hints!

The fuse box is in the compartment under the back seat. A lot of road debris from the rear wheel comes in. Riding on salted winter roads may pay its tall here.





There seem to be no terminals at the end of the cables. Looks like they are directly crimped to the fuse sockets. So, the easiest way to come around for me was to use these kind of fuse plugins. Don't know how to call that in English. Here I crimped one to the red power supply:



Then it fits into the fuse socket, the right one. The left one is a tap to connect my Garmin GPS device.





Used a lot sulfit cleaner



and greased it after that. Hope this workaround works for a while.

[the Ferret]

So it's fixed?