Stalling suddenly while riding? That’s quite a tricky issue.
And it happens intermittently, apparently.
Let’s simplify things step by step.
First, secure solid power and ground connections to the Watanabe unit.
Power goes through a relay, and ground connects directly to the engine.
This way, power and ground no longer run through the harness.
When using a relay, a fuse is essential—the shorter the run, the better.
The battery-to-fuse section is unprotected. If it gets pinched and falls on the frame, it’ll go up in flames pretty quick.
I rarely see customer DIY electrical work, but honestly, I’m amazed how often it doesn’t catch fire. Must just be luck.
The connections on the unit side weren’t great either, so I cut them and soldered direct.
Don’t underestimate fuses either—oxidation is a real problem.
I polished everything.
The right switch connector looks okay.
The switch itself checks out.
Unbelievably heavy throttle—bad routing. I fixed that.
Hmm, the cable color doesn’t match anything… and there’s a bolt sticking out.
I shortened it.
The stopper wasn’t locked—scary. I switched to a flush slim-head bolt.
The throttle cable was a real hassle—and that’s when a Ninja popped out of the carburetor.
Cleaned it up while I was at it.
Rushed work, but phase one is nearly done. I’ll take it for a test ride tomorrow.
