I have a 2007 softail night train and I am having an issue with the fuel pump fuse blowing. When I put in a new fuse and flip the run switch the pump will switch on for a second then blow the fuse. I have the gas tank off and I am chasing wires now. It appears the wires run down the back bone and to the fuse box then to the ecm. I still have to cut off all the plastic covers to chase the wires down and look for a short. What I was hoping to avoid is having to remove my handle bars to check the wires up there. From what I am guessing the run switch activates the system relay which then powers the ignition coil, fuel injectors, and fuel pump. The second relay is what powers the starter. Bike cranks fine and the only fuse to blow is the fuel pump. Any one have any wire diagrams that can help me track the problem? Also any other input to what could be wrong?

 

I hooked a test light to the Orange fuel pump positive and turned on the ignition. The light lot up and the fuse did not blow. Maybe the test light does not draw enough current to blow the fuse but I was hoping to see something. Maybe the pump is to blame. I may take the tank into harley and have them test it. I was also thinking of hooking up the pump to a battery with a 15 amp fuse in line and see if it will blow the fuse

 

Without a wiring diagram you are stumbling around blind, guessing will only get you into trouble.

The relays have nothing to do with the fuse blowing, and neither does the wiring in the handlebars/switches.

The fuel pump circuit is simple, the power comes from the fuse, and goes directly to the fuel pump via the fuel pump electrical connector.

Before you rip all the sheathing off the wiring harness, disconnect the fuel pump electrical connector and see if the fuse still blows.

 

Fuses blow because you have a positive component wire more than likely shorting to ground. You need to start eliminating things until it stops blowing. Either go all the way to the pump and work backwards or work towards the pump. Meter would be a big help too

 

You are all over the place here, take a deep breath, one step at a time.

Disconnect the pump electrical connector, turn on the power, what happens?

 

With the pump unhooked no fuses blow and everything looks as normal. I hooked a test light up to the orange wire and grounded it to the frame. Lights up for the proper time with no fuse blown. I turned the bike over as well and no fuse blown

 

If the fuse does not blow when the pump is unplugged, it tells us that the short is not in the wiring between the fuse and the fuel pump electrical connector.

 

So the better guess would be the fuel pump or the pump wires are damaged. Does the fuel pump tie into anything else electrical?

 

Here's a video on how to pull the fuel pump:

 

Man that guy is hard on the merchandise...

Protect the tank, and wear gloves.