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C900 Bulletin Board
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800S Potential Hotspot
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Posted by KevinO'D (more from KevinO'D) on Sun, 31 Dec 2000 18:46:33 Share Post by Email
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Thanks to the various people who have responded to my questions. I've been maintaining my '85 900S for the past year and a half with only one trip to the mechanic to redo the rear brakes. I have 160K miles now.

Recently the starter went bad. It may have been due to a failure of the ignition switch to disengage the starter or due to shorted wiring. What I discovered is that in the emissions control system where the exhaust is routed to the air filter cylinder might be a major problem. At the end of the exhaust routing tube which goes over the front of the engine on top of the clutch cover there is a right angle piece made of plastic where it attaches to the air filter. This is located in the drivers side front corner of the engine compartment. This right angle piece is completely deteriorated and hot exhaust was blasting my wiring harness for who knows how long.

I discovered that the wiring harness was melted with all the insulation gone and the various wires shorted out when I removed the black rubber intake between the air filter and the intake manifold. This prompted me to take a better look at the general condition of the wiring around the engine. In areas where there was excessive heat exposure the insulation of the wiring had fallen off and I did my best to use electrical tape to reinsulate and replace some wires that were beyond salvaging. This took around 6 hours to restore the wiring harness. Fortunately the end of the harness at the fuse box was not damaged (thank to Andre for his advice).

The bottom line on this is that you need to check the condition of that little right angle piece where the exhaust routing tube connects to the air filter in the emmissions control system. I'm sure that this is the cause of all my woes. I eliminated the need for the right angle piece by bending the exhaust tube and inserting it directly into the adaptor and securing it with a hose clamp. I'm not sure why they didn't do that originally when they designed it but if you want to save yourself a big headache I would do some preventative maintenance and check this area before the wiring harness meltdown melts you.
-Kevin
PS> HAPPY NEW YEAR!!!!!
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