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Exhaust melted my wiring harness to gauges

06 RMK 900 151"
I was riding the past weekend and started smelling burnt plastic, stopped and opened my hood to find my wire harness melted down to the wires. I had extra zip ties and remounted the harness to get off the mountain back to the truck. On the way back the temp sensor worked fine but no tach or speedo. No service engine light but the temp light would flicker on and off. I figured some of the components were grounding out or touching some of the other wires. I got home and re spliced all of the melted wires making sure that all connections were good. After repairing the wires and taking the sled out for a test ride the tach still reads 0 all of the time and the exhaust temp says error. The speedo works sometimes while riding but not always. The speedo will jump when I first start it, but then remains at zero. The sled seems to cut out a little at mid range throttle but runs fine at high rpms. It starts easy cold and is harder to start when warm/hot. I have a feeling that it could be multiple things. I have checked all of the wiring for loose or broken connections, but haven't found anything. I'm looking at getting a new harness, temp sensor, and TP sensor. Any help with diagnosis would be greatly appreciated.
 
Unless you want to spend a little time pinning out your harness wire by wire a new harness is a good choice.
You may ck oil cable/pump adjustment for sticking or obstructions as it should not be related to harness. Ex probe harness is fragile for lack of a better term and rubs on hood,melts,bends need to be checked.....may require a digital wrench ck.
 
New update: Tested all wires and found a broken wire, fixed it and have the speedo back. still no tach or temp. wires in harness all ohm out. Sled runs good for an hour or so then starts to cut out in the mid rpm range (kind of a bog). It also starts flashing a two error code which is the engine coolant temperature sensor. Prob a good reason why my temp sensor isn't working well. ordered another temp sensor. will update after
 
New update: Tested all wires and found a broken wire, fixed it and have the speedo back. still no tach or temp. wires in harness all ohm out. Sled runs good for an hour or so then starts to cut out in the mid rpm range (kind of a bog). It also starts flashing a two error code which is the engine coolant temperature sensor. Prob a good reason why my temp sensor isn't working well. ordered another temp sensor. will update after

Check all the wires that run anywhere near the pipe. The wires that run up to the temp sender melted inside the harness on mine.

Using more oil probably means your stock oil cable is starting to fail, replace it with and FBF throttle oil cable will fix this. I had my sled into the dealer three times trying to get the stock POS to work correctly and it never did.
 
bought a new engine temp sensor and I don't think I can replace it without removing the head. This might be turning into a summer project. Also found out that the two front corners of the gas tank have cracked and now my sled is leaking fuel. Once it is fixed I think I might put it up for sale tired of fixing problems
 
Thanks for the advice on the fbf cable. I plan on doing that since I have half of the sled apart now in the garage. I'm looking for a fuel tank right now and thinking that I might ohm out my temp sensor. I ohmed out the harness and everything checks out good but still no tach or temp :face-icon-small-fro.
 
bought a new engine temp sensor and I don't think I can replace it without removing the head. This might be turning into a summer project. Also found out that the two front corners of the gas tank have cracked and now my sled is leaking fuel. Once it is fixed I think I might put it up for sale tired of fixing problems

Wouldn't you be able to replace the sending unit if you remove the PTO side power valve assembly?
 
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