Guys this is a 2010 Road King, former police bike. Over the winter I put taller handlebars on it.
I extended the wires, checked them for continuity before sealing them up.
I heat shrink every connection, then all nine wires together I put a larger heat shrink over that so I think it's a pretty good installation myself.
With this current configuration however on the right hand switches, my run works, ignition works, rear brake light works however, when I push the large red button which was attached to the passing lights, my right signal comes on. Pushing it again, the signal goes off. The signal switch however will not activate the right signal.

First picture below you can see that there are only three wires on the bottom which seemed to affect the passing lights in the signal. I've tried all the various combinations but I cannot get the signal switch to work independently of the passing lights.

The only caveat is that maybe there is something wired wrong on the top row of wires which you can see from the second picture.

Originally I tried the obvious, simply plugging orange to orange black to Black Etc. But that did not work. Also before I took them apart I took pictures of the originals and I made notes of how the originals changed slightly because the extension wires that came with the kit we're not exactly the same color for instance orange may now be 'orange with a black stripe' but I noted all those differences.

Finally I got the top row (wires numbers 1 through 6). I thought I was down to only three wires not working but since no combination of the bottom three wires (wires 7 through 9) seems to work now I'm wondering if something from the top (wires 1 through 6) has something to do with it.

I'm really reluctant to take it to a shop because I fear they will make a federal case over it and start to pull everything apart.

Also according the the schematic wiring diagrams on the HD website, they don't tell me any different. I never altered the main harness, the female part that goes down the frame, only the wires that go in the bars.

Any suggestions would be great thanks.





cover of the plug is off for testing purposes.... the left side works fine. Just this right side Im having problems with.

 

I'll take a stab at it . I looked up the drawing on https://serviceinfo.harley-davidson.com/sip/ and your thumb is on connector 22B
#1 O/W which powers the stop lamp and right turn switch. The O/W is the Accessory fuse.
2 R/BE from stop Lamp switch, brake lever to Brake Relay
3 GY from ignition fuse gives power to the Off/Run Switch
4 W/BK when Off/Run is in Run the W/BK provides power to start button and System Relay coil. It also gives a signal to ECM that run is active.
5 W/BN this is the right turn signal that goes to the TSM or TSSM if you have security. On the right hand control side you should have continuity between the O/W and W/BN when you engage the turn signal switch, or is it common with the O/V ?
6 BK/RD from start Button to Starter relay
7 O/V From cruise/brake or just brake fuse. This wire is (I believe) power for the Off/Aux Pursuit switch, which must be the big red button. When this switch is on both 8 and 9 have power.
8 GY/BK power to the pursuit flasher which should be you Aux Lamps aka Passing lights
9 GN/R power to the Pole Lamp

If you pull the connector apart and check continuity on the Right hand controls:
O/W should be common with R/BE with brake lever pulled in and with W/BN with turn signal button pressed
GY when off/run is in run will be common with W/BK and it will also be common to BK/RD when the start button is pushed.
O/V will be common to GY/BK and GN/R when you push the Big Red Button.

Did they leave all the Police equipment on the bike or was it removed?

Bill

 

thanks Bill I will see if this is how its connected. if not I'll give it a try and report back. thanks for your help.

- Police stuff was removed. there is still a harness for that stuff but its not attached to anything. I plan to remove it.

your link takes me to the main page HD service, but I saw the drawings there before so I assume you are looking at the same ones.

 

Here are the schematics I found. Do you have ABS?

 

hi Bill, those are the same schematics I tried to use before from the HD Services pages. It seems pretty straight forward. According to the diagrams, the male colours should simply attach to the corpoonding female colours however when I put them together like that, I cannot get run or ignition to work.

Next I took it to "professional mechanic" who got the top row or wires (1-6) in some kind of order where Run and Start will work but then I had no passing lights or signals. He left three wires off that could only go on the bottom row (7-9)

I tried all the different possible combinations of those last three wires. Best I could get was the passing lights to work but the right signal also came on. To Cancel it, you have to put the passing light switch again. (unless you are riding, in which case it would cancel itself) The right signal switch would not work with this configuration however.

With the longer bars, meant longer clutch cable and brake line. Since the bike has ABS, I had to remove the tank to run the brake line from the reservoir at your right hand, down along the frame to the ABS box. After putting the tank back on, the fuel line leaked like a sieve. I guess unhooking the fuel line from the check valve, the orings must have dried out and now cannot form a good seal. I have the orings on order. When they arrive, I will be able to repair the fuel line, then I will be able to start it. If I can start it, I can ride it to another shop (without right signal, which seems to narrow the problem down a lot). This is last case scenario.

This tells me that the professional mechanic's configuration of wires 1-6 is incorrect. One (or more) of those wires must be out of order. Next week when the Orings arrive, I will give it one more shot. If that doesn't work, I will have to drive to to the shop and be at their mercy (which, they are merciless). Last time I took it to "professional mechanic" I had to get CAA (Canadian equivalent of AAA) to flatbed it to the shop, then I rented a trailer to bring it back when said "professional mechanic" could not finish the job. At least by getting the fuel line fixed up, it would be rideable.

I fear that they may say they want to rewire the right side handlebar harness. They would have to take the bars back off which means removing the clutch cable, which means draining tranny fluid (again, after I just did that and replaced with new tranny fluid -- which also means new tranny cover gasket which I just did as well.) and brake line, (which means re-bleeding the brakes) pulling the wires back out, rewiring them (which is unnecessary) then putting everything back together..... I had quotes from several shops to do this job, they ranged from 3500-4500 (CDN) parts and labour. I have not found an honest shop I trust. They would likely do all that work becuase one signal does not work.

I dunno, maybe they would be able to pull the harness out of the bars without removing the bars. The hole that the wires come out of is at the bottom of the bars. Maybe by losing the bars and tilting them backwards, would expose the hole enough to pull the harness out without having to remove the brake line and clutch cable.

I triple checked those wires when installing. Before I installed them, I checked them all for continuity. Im 100% certain that all my connections are good. Frustrating.

 

 

I think it's a good idea to verify what you have. First when you say ignition works do you mean starter?
Let's check what is coming to connector 22B then what's going to the right hand controls. Are the wire colors the same as the drawing? It's important to have O/W, G and O/V power the circuits they were designed to.

What is going to the right grip shouldn't be too difficult....... with all switches in the off position.

Check the wires for continuity on 22A, connect to slot 1 and check to all the others 2,3,4,5,6,7,8,9 then connect to slot 2 and check 3,4,5,6,7,8,9

I don't know if theGY/BK and GN/RD will be common going to the big red button.

Now pull the hand Brake in and tie it and check the wires again you should find the O/W - R/BE in the drawing common release the brake.Hold the turn signal switch on and check the 2 wires from the brake switch with the other wires, the new wire is the W/BN and the wire it's common to is the O/W.

Do the same with the engine start run sw. turn it on nad find the Grey and W/BK, turn it off then push the start and find which one is the BK/R and the one it's common to is the W/BK.

The other three should go to the big red button.

Hope this is clear enough

 

SUCCESS!


Bill! I want to thank you for your help. This was the cinfugutaiton that finally worked. It was a not only a matter of following the colours on the schematic but also since my extension kit did not have exactly the same colours, I had to make note that some of my colours would not be what was on the schematic (or line up with the female part) but between these variables, came the truth!

This is a HUGE burden off my back! Now just waiting for the O'Rings to come in the mail so I can fix the fuel line, close up this plug, add some nice weather, and its ride time!





below you can see the three changes I made. Now everything works! ahhhh I need a cigar. And I don't even smoke!
Its St Paddys day today, maybe it was the luck of the Irish... and Im not even Irish either



I don't know how to mark this thread as SOLVED. It may help someone else.

 

Glad you got it fixed!

There are a few youtube videos showing how to replace the o'rings.

It's warming up here, I bet we get a ride in before April.