Handlebar Electrical Issue
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Stage III
Joined: May 2016
Posts: 3
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From: Acton, MA
Handlebar Electrical Issue
I just posted this over in the Sportster section, but I thought I might post it here too.
Hey All,
I'm having a strange issue with my handle bar wiring on my '03 Sportster XLH1200. I switched out my handle bars the other day. I went from internally wired to external wiring, mostly to save time and in case I want to change my bars again. Now every time I hit a switch (any switch), one of the fuses will pop. Example, I replace all the fuses, turn the bike on, everything apparently working properly, hit the starter switch, fuse blows , hit the hi beam switch, fuse blows, hit the turn signal (either one), fuse blows. Only other piece of info I should add is that when replacing the bushings at the same time I broke the ground wire from triple trees to the base of the risers, I did repair it.
I am having a hard time believing that all of my connections are shorting out but I suppose that could be the issue. I'm thinking it is a common ground but i'm not sure.
Anyone experience this issue before or have any incite into whats going on ?
Thanks
Sparky
'03 Sportster 1200
Hey All,
I'm having a strange issue with my handle bar wiring on my '03 Sportster XLH1200. I switched out my handle bars the other day. I went from internally wired to external wiring, mostly to save time and in case I want to change my bars again. Now every time I hit a switch (any switch), one of the fuses will pop. Example, I replace all the fuses, turn the bike on, everything apparently working properly, hit the starter switch, fuse blows , hit the hi beam switch, fuse blows, hit the turn signal (either one), fuse blows. Only other piece of info I should add is that when replacing the bushings at the same time I broke the ground wire from triple trees to the base of the risers, I did repair it.
I am having a hard time believing that all of my connections are shorting out but I suppose that could be the issue. I'm thinking it is a common ground but i'm not sure.
Anyone experience this issue before or have any incite into whats going on ?
Thanks
Sparky
'03 Sportster 1200
Seasoned HDF Member
Joined: May 2008
Posts: 21,173
Likes: 12,740
From: South Carolina
You have an electrical problem, not a problem that is Sportster specific.
What exactly has been done to these handlebar switch electrical harnesses when you changed the bars?
I like your idea about keeping the wiring on the outside of the bars, it will be the next cool thing to do, right next to removing apes.....
Last edited by Dan89FLSTC; May 30, 2016 at 03:53 PM.
Stellar HDF Member
Joined: Sep 2013
Posts: 3,492
Likes: 610
From: USA
Is it possible that you have the wires in the wrong connectors or in the wrong positions in the connector? I imagine that you had to unpin the wires from the connectors to be able to remove the wires from inside the bars. That's where I would start looking. It sounds like you are now blowing several different fuses (turn signal & brake = accessory; hi/lo = lights). I doubt that pinched enough wires on both controls to cause your problems. Hope you have a wiring diagram. Good luck and post the fix.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
This is a common problem, normally after installing internal wiring in new bars! The most likely cause is either a damaged wire, which can be caused by installing or removing internal wiring, or as 14 suggests, a crossed-over connector.
When a fuse pops, is it always the same fuse?
When a fuse pops, is it always the same fuse?
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Stage III
Joined: May 2016
Posts: 3
Likes: 0
From: Acton, MA
Hey guys thanks for the input so far.
Dan89, exactly what I did was to cut the wires from the harness behind the head light so that I could pull the wires from the old bars. I then re soldered any connection that i needed to and heat sunk the solder. I then ran the wires on the out side of the bars, wrapped in more heat shrink and reconnected the harness connections.
14, Thanks for the insight. I think that is the rout I am going to start on. maybe i just got a couple of wires mixed up. As for a wiring diagram i have found a couple online but nothing actually legible.
GR, Its the same three fuses each time.
Thanks again guys. as soon as a hammer figure this out Ill let you know.
Dan89, exactly what I did was to cut the wires from the harness behind the head light so that I could pull the wires from the old bars. I then re soldered any connection that i needed to and heat sunk the solder. I then ran the wires on the out side of the bars, wrapped in more heat shrink and reconnected the harness connections.
14, Thanks for the insight. I think that is the rout I am going to start on. maybe i just got a couple of wires mixed up. As for a wiring diagram i have found a couple online but nothing actually legible.
GR, Its the same three fuses each time.
Thanks again guys. as soon as a hammer figure this out Ill let you know.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
One fuse blowing is unfortunate, two blowing really is bad luck, but three is just darned awful! Some bad things going on there, by the sound of it, so best of luck sorting it out. Time to make a multi-meter your best friend.....
Seasoned HDF Member
Joined: May 2008
Posts: 21,173
Likes: 12,740
From: South Carolina
Which switch/which fuse?
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