Had my 08 610TE for 1 year.

[aebbern]

just a quick headsup to anyone out there with an '08 TE-610 who likes to ride a little harder than boring old FSR roads. I managed to snap the welds that hold the battery in place on my last ride

My '07 TE610 now has 27,000 km on it. In addition to the battery welds, you'll want to keep a close eye on:
- footpeg bolts
- subframe bolts
- sub-subframe bracket (holds the tail piece on)
- subframe fingers (which bolt to the sub-subframe)
- upper chain roller
- sidestand
- radiator hose clamps

All of the above have failed on my TE. These are fairly well known weak spots on these otherwise great machines.

 

[miller]

thanks Aebbern, I've replaced a lost subframe bolt already, and check the bike out from head to toe before every big outing. I've been battling an electrical gremlin for over a year now that is driving me insane. I keep blowing the 15 amp fuse located on the right side near the seat, which leaves me without any lights,signals,horn,fan etc...thankfully the injection is a different circuit so I don't get stranded. I've torn the bike down searching for the problem to no avail, and the dealer can't find it either...
I'm getting close to giving up and getting rid of her, my patience with exotic bikes is wearing out fast.

 

[hawk]

Miller,

Remove the tank and look at the wiring bundle that goes from the battery to the steering head. I took all of that sealant type tape off and rewound with electrical tape leaving a gap about 1/2 inch between the loops. This will allow the moisture to get out of there. It seems that the insulation is porous on the wires and when moisture gets in there it creates just enough of a circuit to blow the fuse.
I happened to find that when I had my TE. Don't remember which two wires I was reading with an Ohm meter but I suspected it was when the bike got wet. I unwrapped the wires and using a wet sponge held them all together, I then noticed the resistance went way down. Did that and the guy I sold the bike to hasn';t had a problem since. (Or so I'm told)
Just a thought....

 

[scottbc]

I'm getting close to giving up and getting rid of her, my patience with exotic bikes is wearing out fast.[/QUOTE]

Don't give up yet! It may be worth checking out the cost of a complete wiring harness. I had a couple of broken wires in the wiring harness of my 2009 KTM EXC450 and priced out a harness, just over a hundred bucks. I couldn't believe how cheap it was. I ended up repairing mine ( I am an electrician after all ) but was pleased to know that a replacement was very reasonable. You may find the same thing.

Hawk's suggestion is good. I would take it one step further though and inspect each wire for damage. Something that will cause a 15 amp fuse to blow should be very obvious. The modern thermoplastic insulation that is used is generally rated for 600V. Moisture should not be causing your problem. Another thought, check the specs that 15A fuse "may" need to be a 20A. Seems to me that is a lot of load for a 15A fuse. Fuses will blow for no apparent reason if they are subjected to repeated high inrush currents or continuous loads that are close to their ratings. The heating effect will weaken the fuse over time.

Good luck, Scott

 

[cactusreid]

i rode with miller this summer on the loose screw. he was telling me about his electrical gremlins then. i believe he has already replaced the complete wiring harness on the bike.

 

[scottbc]

If the wiring harness has been replaced it should simplify trouble shooting. Check each component after the fuse that is not part of the harness that was replaced. Intermittent problems are hard to find.

Scott

 

[04klr]

time to bring out Voltmeters cousin, the Ampmeter, turn all the affected stuff on and check it, as scottbc said if its even close to 15amps, then the fuse WILL fail (over time) thats what they do, fuses (and breakers) will fail on thermal overload as well as electrical overload.
If not close to the 15a rating then I would be looing for the spot where the wires are rubbed thin (insulation) causing on intermittent short to ground.

 

[miller]

thanks to all of you for the advice...it is much appreciated after so much frustration. I'm going to tear it down again on my next set of days off, and will go over everything again and use the Ampmeter to try to isolate the problem. I did try using a 20 Amp fuse as well, it blew just as quick unfortunately. I also don't believe it is moisture as it blows on boring dry paved roads too...

I have found alot of broken/worn wires that I have either spliced or patched up. The scary part is how Husky has wires going everywhere and their use of zapstraps in odd places...darn Italians. It is still the original harness, the dealer and myself went over it to no avail, but if I don't find anything this time, I'll definitely look into a replacement.

I do love the bike, it has a truly fantastic motor and tranny, and being able to ride singletrack and then wick it up to 120 + in a hurry is pretty damn addictive.

thanks again for all your help...I'll let you know if I find anything or if I decide to give it a Viking funeral...

 

[04klr]

if the 20 blew the same as the 15, that may be a good thing as it shurly must not (best check the load though) be an overload and may well be the intermittent short I was refering to earlier, you would be looking not only for broken/rubbbed insulation AND a nice shiny (void of paint) bit of frame to let the short get a grd.

maybe.

 

[franhoser]

I had the same problem with my 610 in Baja. Found the short on the frame at the steering head. Like 04klr said look for a spot that has paint missing.