Electrical problems with an 03 GT
I have an 03 GT with an instrument cluster that largely does not work and I'm hoping that someone here has had a similar experience with a solution for me.
A couple of months ago I noticed the dash was occasionally behaving unexpectedly after starting the engine. Alternator and sometimes neutral warning would glow dimly, disappearing after a short while, while RPM gague would cease to function.
More recently when turning on the ignition none of the warning lamps are lit with the exception of the flashing ABS check light (not the ABS fault light), after engine start, alt and neutral lit dimly, returning to normal after 10-30 seconds.
This has been highly intermittent, until a few days ago when the problem occurs for much longer on one occasion, then following the next restart the lights and gagues fail to resume normal function and it's how it remains now with the exception that the neutral light no longer glows and the alt light is lit brightly.
The fuel gague and temp gague work, as do indicators hi beam and ABS check, so does the clock but not the gear position indicator. I would check the cluster's board except that the things that dont work are wired directly and not through any board at the instrument panel.
Checking the alternator output by measuring the battery voltage I was getting about 14.0 volts when engine running and have conducted a battery test, post load, with a voltage around 12.9.
Something strange happened on some of the running tests. The alternator produced no corresponding increase in voltage across the battery, no alt light was lit and the temp gague stopped working. Stopping the engine and restarting would resume alternator output etc as before.
The bike's been pulled apart looking for the obvious, bad earth, corroded connections at connectors, etcetera. I found some corrosion on two of the blocks leading to the instrument cluster, think I cleaned them out but not 100% sure right now - the female socket with protruding pins appear bright but have some copper sulphate residues that come from the male plug end of the copper wires. These things have been cleaned inspected seated and reseated several times and it does not affect the symptoms except that I think that the glowing neutral and alternator together has stopped since the cleaning (alt is brightly lit).