Hey folks, allow me to say in advance that I consider the help you all provide to be invaluable.

I tried to start the bike yesterday, it had only been sitting for a few days since I last rode it, and it cranked a few times normally, realized I needed choke, went to start it again and boom all the electric is down. Not sure if it is relevant, but this is a bike that has had it rough. I rode it regularly through this past New England winter. Rain, snow or shine.

Observations:
- First thing I noticed was the speedometer needle was repeatedly circling back and forth, even with the key out.
- I looked at the main fuse and noticed a small spark/flame flashing inside of it.
- There is corrosion on multiple fuses, including the main 30amp ATC fuse.
- None of the fuses appear to be blown. The 30amp has a small, perfectly circular hole in the middle of the bridge but I assume that is there by design.
- Multimeter reading for main fuse is .5 Mega Ohms, sometimes the multimeter doesn't even recognize it, which leads me to believe that either the fuse is blown or I am measuring incorrectly
- I read somewhere about measuring resistance between spark plug caps, and the reading was 22.8 kilo ohms. Also noted that there was no dielectric grease on them.
- The spark plug caps are wayyy harder to pull off the plugs on this bike than my other sportster.

Next Steps:
- I am replacing all of the fuses. Just need to wait for them to arrive off amazon. The corrosion can't be helping anything.
- In another thread someone mentioned replacing the main fuse with a 12v bulb for testing. I am not sure what sort of bulb would have blades that fit.
- If I can get this bulb, I guess the plan would be to hook it up and pull, 1 by 1, the 15amp ATM fuses to recognize where the short is (the one I pull when the bulb dims?)
- I am happy to take more measurements, but I don't really even know where to start. I have a service manual, if you an refer me to a section to read I am happy to do so.

 

What are you working on?

How old is the battery?

Don`t assume it is a short, it could be anything.

Forget about test lights, they are not a troubleshooting tool.

 

It is an 06 sportster, in pretty clean condition. Battery is about 2 years old, and it measured 12.7 volts.

 

You road all winter in New England. The salt corroded all your exposed connectors and ate it’s way into the main breaker. No there’s no vent in the main circuit breaker

 

Are you saying that the bike has no electrical power to any component? Lights, horn, etc?

Have you replaced the main fuse?

Measure the voltage at the main fuse.

Forget about ohms, forget about reading between spark plug leads, test light in the main fuse, all that is junk science.

This is a simple electrical system, follow the troubleshooting tips you get here and you will find the problem.

 

correct no power anywhere.

My next step is going to be cleaning the fuse block with contact cleaner, and replacing all fuses after applying dielectric gel. I will update when that’s done.

 

So I cleaned all the fuse terminals with contact cleaner, replaced all fuses and she’s good as new.

While I was at it, I lubed the spark plug boots and spark plug ceramic with dielectric grease to prevent water and corrosion. I got wondering if I should do the same to the fuses?

i understand dielectric grease is not conductive, but some have said that when the fuse blades come in contact with the terminal, they will remove the grease and connect fine. Maintaining the connection and preventing the build up of corrosion.

thoughts?