IMPORTANT, ALL BF750 OWNERS LOOK!!!


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IMPORTANT, ALL BF750 OWNERS LOOK!!!

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IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 12:51:02 PM 5 votes

mudcrazee

Posts: 8065
Joined: 3/2/2005
From: Gulfport, MS
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I just got back from the dealership, and the service department gave me a copy of this, so I am posting it to help everyone out. It deals with the fan, overheat issues and other problems I have seen people post about.

K-TECH NEWS Vol #18 Issue 1 2005
KVF750 Connector Corrosion Creates Electrical Havoc

Do you have a KVF750 exhibiting strange electrical problems? There have been reports of some very strange electrical symptoms that can be difficult to diagnose.
Typical symptoms are listed below in the order from most common to the least common:

1. Fan does not activate and the engine overheats
2. Meter stays on and the battery goes dead
3. Fuse keeps blowing
4. Engine stalls when 4wd is engaged and does not restart, but it restarts in 2wd.
5. Engine starts without ignition key (when just green button is pressed).
6. Check belt light is flashing.

The cause for these symptoms can be often traced to corrosion forming inside one of the two white plastic 1"x1-1/4"x3/8" joint (BUS) connectors that are taped to the main wiring harness. There is one under the front fender between the front shock towers and another one under the rear fender near the fuel tank.
So far the problem has ocurred only on the rear connector. More specifically, the rear connector/harness is attached to the tube frame just to the right side of igniter/control unit area. If you pry open the cap of the connector, you may find greenish corrosion (electrolysis) formed inside between the bare metal contacts. The electrolysis occurs within the connector because there are positive and negative wire terminals joined together without any barrier to seperate them. On the rear connector the white wires are always on (+), the brown wires are ignition on (+) and the black/yellow wires are ground (-).
If your customers ride in deep water or somehow cause water intrusion into this connector, a special prevention is required because the problem could repeat. After cleaning up the corrosion or the main harness is replaced (because the connector itself is not available seperate), some dialectric grease should be applied inside the connecter and it should be well sealed to prevent further moisture intrusion. The ultimate repair is to remove all of the black/yellow ground wires, solder them together and seal them seperately from the connector.

Please make a copy of this and take it to your dealer if you are having one of these problems. The only way to keep this at the top so everyone can read it is if you all respond. Please respond once you read it. Thanks.

Post #: 1

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 1:43:11 PM 1 votes

Water_Gremlin

Posts: 3923
Joined: 9/22/2004
From: The Last Frontier
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Quote:

3. Fuse keeps blowing

I tried to use my accessory plug in for pump up a tire and it blew 3 10 amp fuses. Looks like I am going to take all the connectors apart and put some diaelectric grease on them. The work NEVER ENDSS!!!!!!!!!

Thanks for hte post

(in reply to mudcrazee)

Post #: 2

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 4:08:52 PM

5string

Posts: 188
Joined: 11/25/2004
From: NC
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I have been lucky so far with my Brute submarine

(in reply to Water_Gremlin)

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Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 8:05:14 PM

mightybrute

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Good advice. Thanks

(in reply to 5string)

Post #: 4

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 8:14:07 PM

OSoBad

Posts: 344
Joined: 1/16/2005
From: South MS
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Yeah that was what was wrong with my Brute. I called the dealership yesterday and he told me all about that. I thought it was a short in the system, but it ended up being that little problem.

(in reply to mightybrute)

Post #: 5

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 8:20:25 PM

srebrute1

Posts: 24
Joined: 8/22/2004
From: Gate City, VA
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Thanks for the information!!!

(in reply to OSoBad)

Post #: 6

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 9:28:40 PM

HavinSomeFun

Posts: 86
Joined: 3/26/2005
From: Little Rock, AR
Status: offline

No problems yet. At least I will no what to look for!

(in reply to srebrute1)

Post #: 7

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 9:39:24 PM

mudcrazee

Posts: 8065
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From: Gulfport, MS
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Quote:

Yeah that was what was wrong with my Brute. I called the dealership yesterday and he told me all about that. I thought it was a short in the system, but it ended up being that little problem.

What was yours doing? I don't remember.

Thanks for the responses!

(in reply to OSoBad)

Post #: 8

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/18/2005 10:30:27 PM

Magellan

Posts: 14
Joined: 4/28/2005
From: ohio
Status: offline

thanks for the heads up, except now I have no need to cuss out my Brute!

(in reply to mudcrazee)

Post #: 9

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 8:25:42 AM

mudcrazee

Posts: 8065
Joined: 3/2/2005
From: Gulfport, MS
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Quote:

thanks for the heads up, except now I have no need to cuss out my Brute!

Trust me, when and if you go to find and clean out the rear connector, you will be cussing, because it is a pain to get to.

(in reply to Magellan)

Post #: 10

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 8:53:29 AM

neckbone

Posts: 324
Joined: 5/5/2004
From: lake charles, louisiana
Status: offline

does anyone have a pic of where the connector is located ?
i would like to fix this problem before it starts.

(in reply to mudcrazee)

Post #: 11

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 9:21:56 AM

mudcrazee

Posts: 8065
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From: Gulfport, MS
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No, the article I got shows where it is located in the frame. OK, I just found it on mine, if you look directly at the fuel tank from underneath the fender on the right side, where the hose comes out of the fuel tank and goes to the check valve towards the frame, directly behind that, is the connector wrapped in electrical tape attached to the main wiring harness.

(in reply to neckbone)

Post #: 12

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 10:17:00 AM

Trapper

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From: MS
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First I've seen of this, I'll pass it along for others
to see. Thanks, mudcrazee.

(in reply to mudcrazee)

Post #: 13

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 10:51:48 AM

The_Brute

Posts: 1053
Joined: 2/20/2005
From: Nebraska
Status: offline

Thanks for the heads up. Mine has been acting weird. Last night I was riding in rack high water and my reverse light would flicker on and off. This is happening while I'm riding in low range in 4wd. Once I was up out of the deep water the light would go off. Well once I got back home and turned it off I decided I wanted to move it so I tried to start it. Nothing. I would hear a fast bzzzzzzt then the display would conk out and I would get nothing. I had to turn off the key and turn it back on and the display would "reboot" so to speak. Once I hit the start button I got that same bzzzzt, then out again. I'll check that rear harness tonight and see if it is all corroded.

(in reply to Trapper)

Post #: 14

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 11:48:04 AM

HDsilverado

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Joined: 7/26/2001
From: Marion Arkansas
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I havent had any problems with mine but im going to check and put some dialectric grease on mine and re-seal it up this afternoon.

(in reply to The_Brute)

Post #: 15

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 11:58:09 AM

Water_Gremlin

Posts: 3923
Joined: 9/22/2004
From: The Last Frontier
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Quote:

I havent had any problems with mine but im going to check and put some dialectric grease on mine and re-seal it up this afternoon.

same here

(in reply to HDsilverado)

Post #: 16

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 12:47:25 PM

mudcrazee

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From: Gulfport, MS
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I'm probably going to do mine this weekend, when I do, I will take pictures and put them in my signature. If someone else does theirs before me and you take pictures, please let me know. The dealership has done quite a few of them and they have been having to remove the rear plastic to get to it.

Your welcome Trapper, I have known about this for about a month, but I didn't have the exact information to put out. The frustrating part about it is that it's not if the corrosion is going to happen, but when. The best thing for everyone to do is to go ahead and clean out the connector and put dialectric grease in it for the minimum protection or see if they can remove all the black/yellow ground wires, solder them together and seal them seperately from the connector.

(in reply to Water_Gremlin)

Post #: 17

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 2:08:55 PM

mudcrazee

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From: Gulfport, MS
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OK, I found the one in the front to. If you want to do the front one first it will be easier to get to and it will help you locate the back one because it is the same connector and you will know what you are looking for. If you look under the right front fender directly behind the top of the shock, you will see the main wire harness. Where it bends around the frame, follow it with your hand, right past the bend wrapped in elecrtical tape you will feel it attached to the wire harness. Its the size of a small skinny matchbox.

(in reply to mudcrazee)

Post #: 18

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 2:38:26 PM

Water_Gremlin

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I may attempt it tonight, and if I do I will take some pics. THe hard part is goign to be reconizing thme.

(in reply to mudcrazee)

Post #: 19

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 2:44:43 PM

mudcrazee

Posts: 8065
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From: Gulfport, MS
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Quote:

I may attempt it tonight, and if I do I will take some pics. THe hard part is goign to be reconizing thme.

WG, the important thing to remember, is that they are wrapped tightly to the main harness with electrical tape. The one up front on mine I found by running my hand along the backside of the harness. Once you feel the square, you will know you found it.

(in reply to Water_Gremlin)

Post #: 20

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 2:47:52 PM

Water_Gremlin

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So this connector is tightly wrapped with electrical tape? Right. So if I find it and put diaelectric grease on it will it solve the stated problems above?

(in reply to mudcrazee)

Post #: 21

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 2:53:18 PM

mudcrazee

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From: Gulfport, MS
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According to the article and what I have seen, yes. If you unwrap the tape and open the top of the connector, clean it out with contact cleaner, then put dialectric grease in it, then wrap it back really good, it should prevent anything from happening.

(in reply to Water_Gremlin)

Post #: 22

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 6:47:39 PM

Water_Gremlin

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From: The Last Frontier
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I located the front connector, but the rear is burried in mud. I dont feel like tearing down my quad for the second day in a row.

Maybe someone should invent plastic that is one piece that has a few connections that is easy to undo and pull off. I know where every single nut and bolt goes on the plastic, that is how many times I have taken it off.

(in reply to mudcrazee)

Post #: 23

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 7:00:16 PM

mudcrazee

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From: Gulfport, MS
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LOL, thats why I am waiting until this weekend. I agree about the plastic, something with less screws would be nice.

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Post #: 24

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 10:07:18 PM

mightybrute

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Tampering with the connectors wont void the warranty will it?

(in reply to mudcrazee)

Post #: 25

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 10:33:03 PM

Water_Gremlin

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From: The Last Frontier
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according to my dealer throwing your leg over the seat will void the warranty. It really depends on your dealer.

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Post #: 26

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/19/2005 10:45:07 PM

mightybrute

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True

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Post #: 27

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/20/2005 9:42:27 AM

mudcrazee

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From: Gulfport, MS
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mightybrute, this is the way I look at it, every connector that I could see I have already put dialectric grease in. This connector is one that is causing problems and you can't see it. Now that I persononally know where it is I am going to do it myself, because I know if I do it now it is a preventative measure. In my initial post I told everyone to make a copy and take it to their dealer if they were having one of these problems only because some dealerships are not even aware of the connectors. I am not by any means trying to give the impression that everyone should tear their quad apart and do this, everyone has to make their own decision based on their own situation. Some people may not have any warranty left, but their dealership may still fix this problem if it happens. All I am trying to say, is the information is here and everyone has to make their own decision based on what they think is best for them. If mine was giving me problems, I would take it to my dealership. On the other hand, my service manager has given me his blessing to go ahead and clean out the connector and put dialectric grease in it because he has seen first hand what happens if it gets to bad. They have changed out 1 complete BF wiring harness and cleaned numerous connectors. He assured me that he would rather see prevention than repair, and even if it still failed they would take care of me.

(in reply to mightybrute)

Post #: 28

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/20/2005 7:36:36 PM

mudcrazee

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From: Gulfport, MS
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I now have pictures in my signature under "Connecter Havoc". I had electrolysis occuring in mine. I pulled out the 3 BUS bars with needle nose pliers and will be replacing them. I think Radio Shack has some. After that I will put dialectric grease in it and seal the entire outside with silicone. Any questions, please ask. By the way, it was not that difficult to remove the rear plastic. I only had to loosen up a few other electrical connecters to pull it out.

(in reply to mudcrazee)

Post #: 29

Re: IMPORTANT, ALL BF750 OWNERS LOOK!!! - 5/21/2005 5:54:49 PM

mudcrazee

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Joined: 3/2/2005
From: Gulfport, MS
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Quote:

I now have pictures in my signature under "Connecter Havoc". I had electrolysis occuring in mine. I pulled out the 3 BUS bars with needle nose pliers and will be replacing them. I think Radio Shack has some. After that I will put dialectric grease in it and seal the entire outside with silicone. Any questions, please ask. By the way, it was not that difficult to remove the rear plastic. I only had to loosen up a few other electrical connecters to pull it out.

I couldn't find any Bus bars, so I did the ultimate repair. I talked to the mechanic at the dealership and he said to cut the wires right at the bottem of the connector and solder all (6) of the black/yellow to eachother, solder all (4) white wires to eachother and all (4) brown wires to eachother. I used liquid electric tape on the wires to seal it up when I was done.
If you decide to do this repair, the important thing to remember is to keep the wires sealed and away from the other wires, that is why you are getting rid of the connector in the first place. Updated pictures are in my signature.

(in reply to mudcrazee)

Post #: 30