electrical system smoking, FUEL PUMP WONT PRIME

[darthpotat94]

Hi everyone,

I need help with diagnosing an electrical issue with my '00 R11S. Long story short, i was riding my r11s, started smelling a burning smell and broke down.



I found the cause of the burning smell to a wire from the handlebar switch that goes to the right hand side of the relay box. The wires melted together and shorted themselves out.

Here's the diagnostic steps I've taken so far:

I found only one broken fuse. The 4amp fuse for the rear light. All other fuses were OK.
My starter relay is broken. All other relays are working as far as I know. My horn relay works 100% since the horn is working so I used the horn relay and the load relief relay and swapped them with the motronic and fuel pump relays to test them out. Fuel pump wont prime. So I assume relays are good and the problem lies elsewhere.

I jumped pins 3 and 5 and the fuel pump works. I am struggling to understand what that means in terms of continuity. Does jumping the relay means that I am bypassing the handlebar and/or the ignition switch? Power comes from the battery and flows through the fuel pump and it works cause I can hear it so the ground is also okay. Am I correct that the problem has to be at the handlebar and/or ignition switch?

I have also tested the Motronic unit itself by swapping it with a good spare one and the fuel pump wont prime either. Is it even possible for the motronic to fry itself since there is a 15amp fuse to protect it?

[Groceryrun]

Looks like fuse number 4, F4, 15amps, feeds both the fuel pump relay and the Motronics relay.
Check to see if the Motronics is getting power.
See if power is going into and out of the Motronics relay.
If the ignition switch is in the ON position, there should be power at "pin 30" of the Motronics relay.

[BigDav]

There are wiring diagrams a couple threads down.

Wiring burns up like that because the intended circuit resistance has gone down either by a wire shorting to ground are one of the loads on the circuit has an internal short.

Although, the fuses are intended to keep that type of damage from occurring.