The new Stelvio NTX comes standard with halogen Hella Micro DE auxiliary lamps mounted on the crash bars and many of them have a problem that can leave a rider stranded.
The internal wiring of the lamps can short-out and cause the entire charging circuit to shut-down. Once you run the charge out of your battery, you are stranded.
The problem is simple and the fix is not difficult.
A single power wire and a ground enters the metal lamp body from the rear through a slip-on rubber boot. This wire should have its excess coiled up inside the rubber boot and NOT stuffed inside the metal lamp housing as is usually the case.
The instructions from Hella clearly indicate this. See page 5 of the installation instructions here:http://www.myhellalights.com/index.php/ ... de-series/
Even though the internal lamp power wire is protected by a substantial conduit shield, vibration WILL wear through the conduit and the wire insulation and the wire will short to the lamp housing if the lamps are powered on.
Apparently, Guzzi has these aux lamps wired directly into the main power circuit and NOT separately fused. When the lamps short-out, they pull-down the entire charging circuit and this will blow the main 30 amp charging circuit fuse designed to protect the main circuit. This will break the circuit from the alternator to the battery. The battery will no longer receive a charge and, as soon as it is depleted, you are dead on the side of the road.
The fix is simple. In an emergency situation, just turn off or disconnect the aux lamps. Replace the blown fuse and get home to fix the lamp short if you cannot work where you are stranded.
The relevant fuse is NOT this one under the seat-
The main charging system fuse that you want to check is behind this cover held in place by three screws on the right side of the bike-
This is the main charging fuse and a spare is provided in the holder-
To fix a shorted lamp or to PREVENT THIS FROM HAPPENING, remove the rubber boot from the rear of the lamps. Pull out the wiring and repair any chafed insulation. Splice together any wire breaks or worn conductor and make sure the wires have good shielding around them.
Slipping rubber material or tape up inside the metal lamp body may provide extra protection against chafing the wires. Coil the excess wiring inside the rubber boot and not inside the metal housing, as the Hella instructions indicate, as you push the rubber cap boot back in place.
You can make an emergency repair on the road but later, better attention to this issue will prevent repeat problems.
I plan to install a separate fuse in the aux lamp circuit, maybe individual fuses on each lamp, to prevent a problem here from taking out the entire charging circuit.
More pics to come.