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Discussion Starter #1 (Edited)
Bike died on the way to Florida. It just electrically shut down. I was sure the main fuse blew, and had an idea why. Wish I had heeded the other reports on the forum and tore the bike down prior to heading out.

I couldn't have broken down at a better time and place. I was heading into Andalusia, AL when everything went black. I coasted into a restaurant parking lot and there was an open spot near a covered porch. Pouring rain out so I got off the bike and under the porch to take in my situation.

I decided that I didn't want to start taking the bike apart in the rain, so I called my ROK roadside assistance. I have a $250 benefit so thought maybe I could get the bike towed to Fort Walton Beach and deal with getting it fixed at the Hotel or by a local dealer. Roadside assistance said the tow company wanted an additional $150 to tow to Fort Walton Beach 75 miles away. I was about to accept that when a couple who were sitting nearby introduced themselves. They are the owners of the local Honda dealership. Rudy offered to open up his shop and have the bike towed there. I told him I had to be at work on Monday and would need to rent a car. He shook his head about the availability of a car rental place, and then to my surprise offered to loan me a bike to continue my trip. I was shocked! Then he probably thought about it a little and realizing that my bike was loaded and it was raining, so he decided to loan me a car from his used car dealership. WOW!

So, I continued on to Florida with a loaner car. I had to wait until the following Tuesday before the Honda dealership opened and the tech could look at it. As suspected, a worn wire that shorted and blew the main fuse. I contacted Kawasaki to see if they will pay their usual warranty rate to at least reimburse me for a portion of the cost since the bike is under warranty and there is not a Kawasaki dealership near Andalusia. They told me to send in the receipts and description of the repair and they will take it under consideration.

Life is an adventure, and sometimes you meet great people during that adventure. I am sure there are great people everywhere, but the folks in the south are top notch and I am so glad I live in the south.

PLEASE PLEASE pull the tank trim and inspect your wiring. Better yet, wrap some additonal tape around the wires before you break down in the middle of nowhere. I now wish I had.

If you are ever passing through Andalusia, stop in at Jackson Honda and say hi.

Here are links to other posts regarding this problem.
http://www.vulcanforums.com/forums/showthread.php?t=34730

http://www.vulcanforums.com/forums/showthread.php?t=31748&highlight=houston+problem

Update: Got the check from Kawasaki reimbursing me the amount I paid the Honda shop to repair the bike. Thank You Kawasak for standing behind your bikes.
 

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I've read the other posts on this subject but you've pretty much convinced me now :)
Glad to hear things worked for you through the people who helped along the way. Could have been a real drag if that wasn't the case.
 

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Guess maybe I will do just that this weekend and check the wiring.

Glad things worked out so well, it does help reinforce our faith in humanity once in awhile.
 

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Man...bummer. Glad you broke down in about the perfect situation though! Good karma!

Is this a 1700 issue or just a Voyager issue?
 

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I recently went through a similiar breakdown in harrisburg, PA. And I was able to roll into high strengh vtwin motorcycle shop. Not the south but the hospitality was amazing. A family owned cycle shop that fixed my bearings for $69.00. Including a recomendation of what part of town to stay in and a ride to and from hotel. Great people. Sent them a thank you note with a gift when I got home. Great people and very thankful.
 

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Man...bummer. Glad you broke down in about the perfect situation though! Good karma!

Is this a 1700 issue or just a Voyager issue?
It is a 1700 issue, I checked my wires a couple of months agoon my 1700 classic and I could see a rub mark, fixed it then so I don't have an issue later
 

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So do you need to have used most of the fuel in the tank, then remove the tank to get to all the wiring?
 

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Had my tank off last summer when I installed my Cobra PowerPro, and it only takes about 5 minutes or so. If I remember right, when you unplug the fuel line, the remainder doesn't drain out... someone correct me if I'm wrong, I know it doesn't sound right:confused:
The ignition bezal just pops off with upward pressure. Unplug couple of lines and the tank can be pulled back from the forward mounts.
It would for sure be a lighter in weight with less fuel but I think it will stay in it either way.
 

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As others have said before. The wirs can be inspected by just removing the tank trim. If the wire lays close to the frame, even if it is not rubbed I recommend protecting it. Remove ignition trim ring, remove seat, remove two bolts that hold tank, move tank up and to the right and support it. Protect wire with electrical tape, rubber hose, or split wire loom. I did not have to completly remove the tank. If your bike is under warranty I would ask your dealer if they will check it out.
 

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Totally agree on that statement.
Has anyone ever brought this up with Kawasaki officially? Sounds like its time!
 

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happened to me last summer

middle of nowhere VT. under warranty, but cost me most of the day, 50 tip for awesome service and 50 for gas to a Good Sam who had a trailer
 

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Discussion Starter #13 (Edited)
Totally agree on that statement.
Has anyone ever brought this up with Kawasaki officially? Sounds like its time!
I am talking with Kawasaki Customer service about getting reimbursed. The only way to force a recal is to report to the national highway safety folks. I told Kawasaki that if this had happened at night on a busy road I could have been run over because you lose everything.

You can go here to file a complaint.

https://www-odi.nhtsa.dot.gov/ivoq/

If the master fuse had not blown a fire could have started.

If this were to happen at night you would have no lights. Have you ever shut off the lights on a dark road while going 50 MPH? A crash is a real possibility and/or getting hit while trying to brake since you have no tail lights at all.
 

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Great topic, thanks for sharing this. Popped off trim and 2 bolts on tank and found exactly where brown wire (along with 2-3 others) rub. Brown wire had small sign of rubbing and saw inside of tank where it was shiny and the rest dusty.

Used electrical tape and layered area down from end of protective coating - plug. Inspected main harness and all is good and protected.

Highly recommend EVERY Vulcan owner performing this simple 15 min fix. Wires are located upper left front near ignition switch, but you need to take off trim, gently work off ignition trim (round piece that goes around lock). I used back of my Kawasaki key "rubber edge" to gently pry it up slowly. Pop seat and unbolt 2 bolts where seat connects into bracket up front by bottom of tank. I had a full tank of gas, so weight of fuel won't be an issue as you don't need to tank completely off just enough to remove it from front rubber mounts and let it rest on the mounts while you go to work with electrical tape.

When putting tank back on round rubber mounts up front, pay attention to rubber line that is on right front side. Don't want to get that caught up with bracket that fits into rubber mounts. Once lined up on rubber mounts (use flashlight to inspect both sides) gently apply pressure to top of tank and push down. I used a soft buffing cloth across the tank so I didn't scratch or get finger prints all over tank. also would be a good time while trim is off to put fresh coat of wax on before putting trim back on.
 

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If I remember right, when you unplug the fuel line, the remainder doesn't drain out... someone correct me if I'm wrong, I know it doesn't sound right:confused:
Yep. On a fuel injected bike if you disconnect the tank after the fuel pump (which would be that hose) then it won't leak out (except maybe a dribble). If the fuel pump isn't spinning, then no fuel will come out of the tank!

Would still recommend removing the tank when near empty just to make it easier though!
 

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I checked mine this morning, no rubbing at all, nearly 13k in miles now. I went ahead and taped the wires anyway, better safe than sorry.
 

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Checked mine today (7,000 miles), might have been some very slight rubbing but that could also have been my imagination. Either way it's wrapped up now.
 

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I checked my wiring this weekend on my Nomad. Most of the wires seem pretty well wrapped under the tank and I didn't see any of them close to rubbing the tank or frame. I suppose I could be looking in the wrong place, but it all looks good to me.

I also managed to get my oil changed. Now running synthetic Mobil1. :)
 

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I checked mine yesterday too. The wires are routed and protected well, but I wrapped them just in case. I wonder if this is a problem when they are put together out of the crate on some? Maybe the dealers are being careless in assembly?
 
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