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Jeff,
It sounds like you found your problem elsewhere; however,
I posted some time back when I replaced the wiring harness from the headlight shell area to the instruments. This harness is an invitation for trouble. The rubber sleeve around the harness is ty-rapped tightly to the connector body in the headlight shell. The other end is about 6" higher at the instruments and open! The design of the harness cover at the instruments on my T-100 is such that moisture can easily get into the protective sleeve--especially if you ride in the rain. The moisture cannot escape at the bottom end and can collect at the connector! No other connector inside the headlight shell is done this way.
My specific problem was the loss of instrument lighting on the speedo. What I found was corroded splices inside the harness sleeve--one splice had come apart. The connector in the headlight shell was full of corrosion. The replacement wiring harness had the protective sleeve ty-rapped tightly to the bottom connector. I cut the ty-rap, shortened the sleeve by 1/2", and put an "anti-oxidation" compound on the connector prior to install.
My dealer covered the new harness ($115) under warranty. I talked to the mechanic, and he said he has replaced a few of these. He blamed the problem on poor splicing of the instrument power wires inside the harness. The shrink rap that covered the splices in my original wire harness were not installed very well, IMHO.
Larry
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Larry
2003 T-100 (790cc), NARK, NH Togas, 8100 rpm rev limiter, 158 main jets, 42 pilot jets (less than 1 turn out on pilot screws), stock needles--no shims. 13 A/F ratio from 1100 rpm to 4000 rpm; 12 A/F ratio from 4000 rpm to 6000 rpm; 13 A/F from 6000 rpm to 8100 rpm.:D
2007 Tiger 1050--White:D--SW-Motech crashbars, Skidmarx rear hugger/chain guard, Calsci +7 windscreen.
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