Join Date: Oct 2005
Location: Albuquerque, NM, USA
First off, pardon me if you're an electrical expert. It didn't sound like it, so assume not.
I'm not near my LT shop manuals, so I'm basing this on electrical troubleshooting experience.
I haven't taken my grip off yet, but I'd bet it's easier to get at the connection where the wire attaches to the heating element at the grip. Also, the throttle action probably puts stress on the wire that attaches to the heating element. I wouldn't be surprised if the strain relief failed, resulting in a crimp, soldier or screw connection failure, whichever the case may be.
If you find the grip side connection is solid and you don't detect a problem by visual inspection, check the other end. If that connection is solid, get out the continuity tester (preferably a muliti-meter, which may be needed if the fault is not easily found). If there's no continuity from one end of the wire to the other, you'll be replacing the wire or doing a bypass around the broken/frayed wire (assuming you can locate and reach that failure). The decision to replace or bypass is a matter of time, materials, and whether you can find the point failure.
If you get continuity from one end to the other,
* the heating element in the grip may have failed
* the wire insulation may have worn thin and be leaking current to ground. The paint could provide enough resistance to limit current or an insulation failure could be in the early stages (again limiting current to ground). A leak can be diagnosed by measuring the resistance from the wire to the motorcycle ground. If you take this measurement, disconnect battery ground cable. With the ohm meter on the highest setting, megaohm scale, you should measure open.
A few other possibilities may come to mind later. If you want advice from me after checking the connections at both ends, verifying continuity, and checking for a current leak, PM me to get my attention (I might not remember to check this thread again). I have a few electrical troubleshooting tricks up my sleeve, but this is getting too winded to say more without further info.
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2000 K1200 LTC - Canyon Red