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June 14th, 2011, 05:16 PM   #1
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WIring harness 2009 FE450

Once again, my bike has failed me. It quit on the final lap, about 1 mile from the finish of the Funky Chicken National last weekend. I just got it apart today, and am pretty sure the problem lies with the electrical connector right at the fuel injector. Well, that and possibly a damaged wire harness. I removed the harness for visual inspection and have found(so far) 5 spots that have chaffed thru the housing on the wires. As I have attempted to trace them out, they all appear to be unused parts of the system, but going forward, I have two choices.
1. replace the one connector that I believe to be bad and patch up the worn bits
2. Replace the entire harness.
I am leaning towards option 2, but have not priced out a harness yet and may quickly go for option one.
My questions are, where could I get that one connector. I see no identifying marks on it, so don't know where to look. Suggestions? And is the harness one orderable part, and where would I get that ordered? I have no local Husaberg support and am on my own on this one.

For history on this particular bike, and what I have done looking for the issue, see 'Aftermarket fuel pump' thread

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BRN2RDE
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June 14th, 2011, 07:33 PM   #2
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Re: WIring harness 2009 FE450

My bike had the harness replaced under warranty and ended up being a root cause of an on going issue (Kendall husaberg section "that was a long push") it took the dealer about 20 hours to get the problem found and fixed the harness runs about 650-700 bucks for a new one
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June 14th, 2011, 07:59 PM   #3
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Re: WIring harness 2009 FE450

the harness runs about 650-700 bucks for a new one
So, I will be looking for the connector at the injector....I can buy alot of heat shrink connectors for that much money. 3 years and 5000 miles in I don't hold out much hope for warranty replacement of the harness.

Any dealers on here care to identify that little part for me? I''ll buy it from you
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June 14th, 2011, 10:21 PM   #4
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Re: WIring harness 2009 FE450

Would you mind letting us know where the five wear points were so that we can check our bikes? I have the harness above the shock wrapped in part of an old hd tube because I heard it could wear there. I'd sure be interested to know other potential wear points. Thanks, and best of luck getting yours running right. You've had more than your share of bad luck with it.
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June 14th, 2011, 10:39 PM   #5
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Re: WIring harness 2009 FE450

My friend srink wrapped some of my connecters after all the crap I had with mine, the bike has been perfect since when putting the harness back we made sure nothing would chaff it again
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June 15th, 2011, 05:28 AM   #6
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Re: WIring harness 2009 FE450

Well, just off the top, and still needing further inspection, I have 3 wires that are worn thru up behind the front number plate, right at a plug. I assume it is lighting related and I have no lights, but will still get some attention. Looks like the air temp wire that goes to the airbox got hot from the exhaust and melted the housing off, and one white wire about an inch from the ECU plug has a bare spot.
I will dip the whole harness in cleaner and inspect everything futher before reassmbly. Even with all that, I am convinced the connector at the fuel injector is the cause of my problems. Fool with that and bike runs better.
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June 15th, 2011, 08:24 AM   #7
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Re: WIring harness 2009 FE450

I think I may have just answered my own question. The connector for our fuel injectors appears to be the same one used by Suzuki Hayabusa's. Look at the last connector on this page. I have ordered a pair, to have one and a spare. I will let you all know if it fits. http://www.injectorrx.com/fuel-injector-connectors.html
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