Husky electrical fire risk fix. – OLD Bull Trailriders

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November 4, 2009 at 8:14 pm #97472

Mick D
Member

Here is a quick cheap fix that KTMBULL showed us recently, to ensure you don’t have big dramas if you own a late model Husky.
Due to a cable routing blunder, some Husky models have the potential to short out the main power lead from the battery and if they do short out there is a fair chance your bike will catch on fire or melt your battery before you can disconnect the power.
The main power lead from the battery is routed through an alloy bracket in the frame, ,which has the potential to wear through the insulation and short out.
KTMBULL has witnessed a bike try and self combust out in the bush first hand due to this problem.

You can see in this pic how it runs through the bracket

These pics were taken of Kram140’s new Husky 310 and as you can see in the next pic that the bracket had already started to wear into the insulation and this bike would be lucky to be 3 months old!!! The potential for a electrical short in the future is there!!!

To minimize the risk, it is a simple job to take the cable out of the bracket and reroute it away from any potential insulation wear.

A handy tip, that may save someone some grief out in the bush in the future. Thanks KTMBULL for the advice.

November 4, 2009 at 8:36 pm #159525

Paul
Member

:ohmy: WTF?
How could quality control miss that?
But then, I am an electrician

Did they recall the bikes?

November 4, 2009 at 8:40 pm #159527

Greg
Member

Nice spot Bull

TB

November 4, 2009 at 10:32 pm #159529

Anonymous

It’s got sweet FA to do with quality control. Who designed it like that, who checked it and who approved it for production???

November 6, 2009 at 4:29 am #159548

Bill
Member

Moto wrote:

Quote:

It’s got sweet FA to do with quality control. Who designed it like that, who checked it and who approved it for production???

Husky know but have put a double insulated wire now but still route it tru there, the bike i saw do it in the bush was a 08 te450 low hrs and the owner works as a mechanic at the local husky dealer and he let them know what the problem was and im sure there has been others that have done it as well i would also put some tubeing around it as well but didnt have any left after i did Thirstys one it was a lot further rubbed through than krams was

November 6, 2009 at 9:24 pm #159811

Woodsy
Member

Cheers again Bill. Might change it back before the warrenty runs out and see if Husky will give me a new bike after it burns to the ground. :ohmy: Maybe not. :blush:

November 6, 2009 at 9:34 pm #159865

Paul
Member

Actually Mick, I’m not sure I like the look of that fix.

I would re-route the cable/s away from the lug, (up over it or completely away from it) and tie it to the square tube of the subframe or something.
Just get it away from any sharp/square edges.

Same treatment for the other cable you’ve left inside the lug please.

Electricians rule

November 6, 2009 at 10:58 pm #159866

Bill
Member

WikdBeemer wrote:

Quote:

Actually Mick, I’m not sure I like the look of that fix.

I would re-route the cable/s away from the lug, (up over it or completely away from it) and tie it to the square tube of the subframe or something.
Just get it away from any sharp/square edges.

Same treatment for the other cable you’ve left inside the lug please.

Electricians rule

there is nothing to rub on other than the battry case and the power wire short out on the sub frame that is what we are trying to stop if you replace the wire with a longer one you may find a better rout and the other one is the earth so it can rub all it wants dont even need to be insulated

a bit of tubeing over the power wire as well didnt have any in the photos fitted

November 6, 2009 at 11:32 pm #159869

Paul
Member

OK Bull.
That’s just what I would do if it was my bike.

Also, the copper conductor is not much tougher than its plastic insulation and when the plastic wears through there will be copper corrosion to make things “wear out” faster.
The earth wires is just as important, it completes the circuit back to the battery.

November 7, 2009 at 2:22 am #159870

Alex
Member

Is it not as simple as “fixing” the cable so it won’t move within that bracket? Cable tie both sides and the job is done (which is probably what the designers intended). I agree that the bracket is a bad idea. I would do what Wikd suggests too, run the wires away/around it.

November 7, 2009 at 10:00 am #159530

Greg
Member

WikdBeemer wrote:

Quote:

I would re-route the cable/s away from the lug, (up over it or completely away from it) and tie it to the square tube of the subframe or something.
Just get it away from any sharp/square edges.

Same treatment for the other cable you’ve left inside the lug please.

Yes why still run it through and risk over time it rubbing through the extra protection as well

WikdBeemer wrote:

Quote:

Also, the copper conductor is not much tougher than its plastic insulation and when the plastic wears through there will be copper corrosion to make things “wear out” faster.
The earth wires is just as important, it completes the circuit back to the battery.

Its funny when teaching basic electrical and heavy duty electrics trying to make people understand the importance of the earth circuit WTF :ohmy:

Just my opinion of course

TB
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