During my trip to Georgia this spring, I had an unexpected Power Commander malfunction. You can read the details here.

At the time, I was puzzled as to the cause.

My post-autopsy findings revealed the following:

The DynoJet Power Commander wiring harness had worn through the wire jacket at the point where it goes under the tank. The worn spot was the size of a small pin-head. Apparently, the bare spot shorted out against the tank. (confirmed by DynoJet)

My guess is that micro-vibrations from the tank against the wire can abrade through over time.

The fix is very easy. You'll need the following items :

• some electrical tape
• 12 inches of clear PVC tubing 1/4inch or so in diameter ( just eyeball it). But don't get it too big as it might cause binding at the tank/frame junction. (cost approx 15 cents)
• a small razor knife

• Wrap/insulate the area surrounding the bare spot using electrical tape.
• Using a razor knife, slice down the length of the pvc tubing.
• Apply it over the wiring harness.
  Note: If you have trouble getting the tubing over the harness, bending it over backward gently will facilitate the install.
• Run a length of tape down the tubing to seal it.

That's it!
It's now re-connected and running flawlessly.

Bruno
Montreal, Canada