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Ok, now that the battery is known to be good:
Clean the battery posts and the battery cable terminals.
Reconnect the battery cables using the process described in the factory service manual (important).
Turn ignition switch on and with your voltmeter, read the voltage at the copper colored terminal on the main (30 amp) breaker.
I hooked the battery up compliant to the service manual instruction.
The emergency shut off switch is not on. Run is switched on.
I went ahead and tested the main breaker and then all of other breaker terminals. All the breaker terminals both copper and silver are reading 13.2. See the breaker structure below from the service manual. I replaced all of those breakers except the ignition one I believe,
Found this looks like they had a problem with the 30 amp breaker
Model : HARLEY DAVIDSON
Year : 1990, 1991
Manufacturer : HARLEY-DAVIDSON MOTOR CO.
NHTSA CAMPAIGN ID Number : 91V117000
Mfr's Report Date : JUN 21, 1991
Component: ELECTRICAL SYSTEM:FUSES AND CIRCUIT BREAKERS
Potential Number Of Units Affected : 61386
Summary:
MALFUNCTIONING 30 AMP CIRCUIT BREAKERS DURING OPERATION CAN RESULT IN DISRUPTION OF THE ELECTRICAL SYSTEM, INCLUDING LIGHTS, IGNITION, AND ACCESSORIES WITHOUT PRIOR WARNING.
Consequence:
DISRUPTION OF THE ELECTRICAL SYSTEM RESULTS IN LOSS OF HEADLIGHTS AND STOPLIGHTS, MAKING VEHICLE LESS VISIBLE AND INCREASING ACCIDENT POTENTIAL OF THE RIDER.
It's not that complicated. If you're not getting ANY POWER ANYWHERE it's the main breaker or the ignition switch.
But seeing as you're getting 12 volts all over the place, check your ground and you main plug harness.
I have replaced the main breaker and ignition switch last summer. When I did troubleshooting at that time my ignition switch was getting 13v to all the wires going to the ignition switch.
How would I check my ground wire? Are you referring to the one from the battery?
Then how would I check my main plug harness?
Last edited by Pfarley1; Jun 13, 2018 at 08:08 AM.
I have replaced the main breaker and ignition switch last summer. When I did troubleshooting at that time my ignition switch was getting 13v to all the wires going to the ignition switch.
How would I check my ground wire? Are you referring to the one from the battery?
Then how would I check my main plug harness?
the ground to the battery is what you checked with the jumper cable.
This does not mean there is not a ground problem somewhere else.
if a particular component is not properly grounded it won’t work.
If you have 12 volts hot to the ignition switch when you turn on key you should have a hot wire leaving that was not hot with the key off if this is true the switch is good.
Use your wiring diagram and work your way through the bike.
but since nothing works it is likely a main fuse breaker or wire,start from the battery and trace in order checking for 12v and ground at each step.
I replaced my main breaker after a recall notice I got for my 1991, but the OP has changed all the breakers. All I can suggest is make sure the big ground wire from the battery is not corroded internally. Also check the big red wire to the starter for corrosion. The small red wire on the battery goes to the main circuit breaker. Take your meter and trace the voltage to every point. Start at the main breaker, one side, then the other, then the green and white (which return power from the switch to the other breakers). It can't be that hard, the wiring on a 1991 is pretty darn simple, which is what makes the 1991-1994 great year bikes to own.
You are reading system voltage at all breakers with ignition switch on, now you need to trace one one circuit at a time, to find out what the issue is.
Start with the lights circuit, unplug the connector for the tail light and read voltage at the blue wire in the connector (main harness side of connector).
Unplug connector 2 A/B and read voltage at 2B (blue wire, main harness side of connector).
Last edited by Dan89FLSTC; Jun 13, 2018 at 06:02 PM.
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