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Discussion Starter #1
A friend of mine bought a stunted 1995 CBR900rr last fall and we have been slowly rebuilding it. The original harness was cut into pretty bad so he decided to replace it. He picked up a harness off of eBay, which ended up being about 95% right. The major issue was that there was no plug for the fuel pump. I ended up splicing in the relay and plug, and it worked to my surprise:) Obviously the fact that this plug was not on here makes me believe the harness he purchased was not the right year, but pretty close.

Ok, here are quite a few questions. Any and all help is appreciated.

I got the bike to fire up last night. But it sounds like it isn't firing in the right order. There are two ignition coils above the carbs. Now I do not know which wire goes onto which plug on the coils. On one side I have a Bu/Y and a Bl/W, on the other side I believe I have a Y/Bu and a Bl/W. Does anyone know which color goes to which prong?

Right near the ignition coils there is another large plug that comes out near the center of the carbs. This has 3 wires running into it. There is a Y/R, R/Y and a Bu I believe. I have absolutely nothing to plug into this. Does anyone know what this may be? Is it possible it's a plug that isn't used on a 95 900rr? It isn't listed on my schematic at all, and I don't believe it was not on the old harness.

Only the left turn signal works. When I hit right on the switch, the relay does not click. When I hit left it clicks and both front and rear signals change fine. Is this a problem in the relay or my switch most likely?

The bike will also only start with the kickstand up. After it starts I can put the kickstand down and it continues to run. This is a problem with the kickstand switch?

The indicator lights on the cluster are quite screwed up as well. When the turns blink, the neutral light blinks. When the brights are on, the oil light is on. I don't know how these would have gotten all mixed up, but that's also not a major concern.

There is a fairly large exhaust leak on cylinder 1. It putters pretty loud. What should be replaced first in order to eliminate this leak?

Thanks for any help with what has somehow become my nightmare!
 

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Hi Keyhole

I can help you i think

1. the coils.. the black wires go to the black connector and the coloured ones go to the blue connectors at least i hope they do. let me know

2. the three wires you have connect to the throttle sensor. my 1999 has this not sure if yours does...

thats all i can think of for now but ill let you know if i think of anything else

Jay
 

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Discussion Starter #3
Yea I was looking at some wiring diagrams and the later models have that plug listed, I don't believe the diagram I have for a 95 has that plug listed...
 

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no worries.

if the bike starts thats a plus...

more than mine does at the moment lol

Apparently the only problem with the sensor would be at high revs you could find a dead spot..

but it wouldnt stop the bike from starting

Jay
 

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Discussion Starter #6
I wonder if the 95 even has that sensor. And if not, will I run into any issues not having anything plugged into that.

It fired up yesterday after a couple of tries, so that made me feel good about the time spent on it.
 

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Discussion Starter #7 (Edited)
I just checked the 95 wiring diagram. There is NO TPS sensor on the 95 model. That should not affect anything that I don't have one.

Although now that I look, the difference between the 95 and the 99 is that the 95 has a clutch diode (what is that?) and the 99 has a TPS sensor. The plug at the ignition module has different wires going into it as well.
 

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hi keyhole..

the clutch diode is part of the clutch switch... look at the back of the handle you should see two wires

this is the circuit that is designed to stop the bike from starting if it is in gear... you can start it in gear if you hold the clutch in..

i thought the 99 model had that as well.. think its located in the fuse area... little black box if i remember correctly.

this is where i start running out of knowledge at the mo... mine wont start due to a problem but i am removing my loom tomorow so i should know more then

if you have just changed one how hard / long did it take you to fit it.. just so i have an idea..
anything i should look out for...

thanks

jay
 

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Discussion Starter #9 (Edited)
the clutch diode is part of the clutch switch... look at the back of the handle you should see two wires
Ok thats hooked up correctly.

if you have just changed one how hard / long did it take you to fit it.. just so i have an idea..
anything i should look out for...
Took my buddy about 30 minutes to route everything and plug it in incorrectly. Took me another 3 hours to sort everything out :rotfl:
 

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ha ha

in that case ill make sure i label everything lol

im hoping i find the problem with the cable else im all out of ideas...

does your bike run ok when you get it started or does it cough and splutter
 

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Discussion Starter #11
It kind of runs ok...I don't think the coils were plugged in properly, so who knows how it really runs.
 

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i notice you needed to splice in a fuel pump relay...

my 99 model doesnt have a fuel pump...
i wonder why your version does yet my version dont....

i would have thought it would have been a standard thing.
 

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Discussion Starter #13
minijay said:
i notice you needed to splice in a fuel pump relay...

my 99 model doesnt have a fuel pump...
i wonder why your version does yet my version dont....

i would have thought it would have been a standard thing.
We couldn't find the fuel pump on my buddies 99 either. Apparently the harness we put on must be for a 99.
 

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minijay said:
i notice you needed to splice in a fuel pump relay...

my 99 model doesnt have a fuel pump...
i wonder why your version does yet my version dont....

i would have thought it would have been a standard thing.
From 1996-1999 all the 900RR's were gravity fed. No pump.
 

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Discussion Starter #15
Got it running and out on the road last night. Actually ran pretty good, but the battery was so dead.

There were two seals actually missing from the header, so replaced all 4 and the exhaust leaks are pretty much gone.

The right turn signals still don't work. Tried another switch and another relay. Neither would work. What else could possible be the problem?
 

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Discussion Starter #17
Wouldn't the relay still click if there was a blown bulb? I can get it to click left even if nothing is hooked up.
 

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Actually if the bulb was blown everything on that particular side should blink faster.

You have a bad wire somewhere. The only way you will find it though is to just dig.
 

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it should be either the solid light blue. solid orange or the black with white strip cable that is causing the problem if i remember correctly

try taking a + & - from the battery and see if it works then. should give you an idea of what cable you are looking for..

the black with white strip is a common.. + i beleave
but just check to be sure...

Jay
 

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Discussion Starter #20
Ok, a few more issues worked out this weekend. Got all the turns working, turned out it was a blown bulb. That was simple.

Got the bike out and took it for an extended ride this weekend. The engine runs great. Pulls hard all the way, I really like the way it runs.

New issue though. Put about 40 miles on the bike and we were on the home stretch coming home. We stareted riding a little more spirited and when my buddy twisted the throttle suddenly there was a loud backfire and the bike just died. Tried to restart and zero power. Turns out the main fuse blew. I assume the backfire was from an overload of gas after the fuse blew and there was no spark.

Replaced the fuse and the bike ran great all the way back home. Any ideas as to what would suddenly make the bike blow the main fuse when he twisted the throttle hard? I had been out on it and had it wide open, along with another buddy of mine too. Could this have just been a fluke?
 
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