I bought a Thunder-Heart Micro Harness and OEM switch kit for a non-EFI, non-CANBUS bike. Below are links to the products I bought.

I got it wired up per the instructions. I even called Thunder-Heart to verify that things were hooked up correctly.

I also tested the switches and the harness with my multimeter and things appears to be working.

Long story short, something is not quite right:
When I hit the Hi-beam switch, the headlight remains on Lo-Beam. There is not even a flicker when switching to hi-beam.

Secondly, the horn works just fine when the Headlight is on Lo-Beam, but if I switch to Hi-Beam, the Horn won't work.

What do I have wrong??

Thanks for the help!!
D

http://www.jpcycles.com/product/382-824
http://www.jpcycles.com/product/362-098

 

Year and model bike?

 

I figured it out. The wiring diagram supplied by TH didn't work...had to figure it out by trial and error.

To answer your question, telling you year and model wouldn't help.... I built the bike from a bunch of different parts from different years and as I said above, the wiring harness and switches are after market.

It's a softail. 2008 frame. 2011 motor. EFI 96ciB motor converted to carb. Thunder Heart wiring harness. Thunder Heart stand alone ignition module.......

 

Johnny Cash comes to mind here! LOL

glad you got it figured out. Wiring can be a nightmare sometimes..

 

It definitely was for me because this was my first bike resurrection and I didn't know anything about CANBUS wiring, EFI vs carb, etc, etc. ...but that was the whole point of doing the project, for the experience and to learn.

In case anyone cares...regarding the electrical problem I originally had with the horn and hi-beam/low-beam:

With a multi-meter I determined which wire from the hand control switch was the hi-beam and which was the low beam. I had to do this because I had already installed the hand controls and didn't want to take them apart again to see which wires were running to which switches.

Per the TH wiring diagram, they said to hook the Switch Hi-Beam wire to the Harness Hi-Beam Command wire. They said the low-beam is on all the time and the hi-beam/low-beam switch is a relay that is either off (low-beam) or on to send the hi-beam signal. However, the Switch also has a Low-Beam wire....TH said to not use that wire. The wiring diagram even shows NOT using that wire.

Putting the Switch Hi-Beam wire to the Harness Hi-Beam Command wire turned on the Low-Beam, but when switching to Hi-Beam, nothing happened. After several days of jacking with it, I decided to just figure it out by trial and error. During one of the trials, instead of hooking the Switch Hi-Beam wire to the Harness Hi-Beam Command Wire, I decided to hook up the Switch Low-Beam wire to the Harness Hi-Beam Command Wire. That worked.

With that fixed, I still had to solve the horn problem. As you recall, the horn would work when the Lo-Beam was on, but not when the Hi-Beam was on.

The wiring diagram showed the Hand Control Power Wire being spliced with the other Blue power wire (forgot what it was for).

I was suspicious that the problem was with the power wires so I decided to run one of the auxiliary power wires from the wiring harness up to the Blue Power wire (not splice it with the other). That solved the problem. The horn works no matter where the Hi/Low Beam switch is set and the Hi/Low Beam switch actually works.

Here's a picture from last night:

D