Wiring Issues

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Aug 5, 2012 | 12:04 AM

StayPuft

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1st Gear

Joined: Aug 2012

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From: Washington

Wiring Issues

I've got a 2003 XL883C and I just installed drag bars, and new grips and levers, at some point during disassemble or reassembly I think I may have damaged the wiring to my controls. After install I blew the fuse for my ignition system, I replaced the fuse hoping that it was a one time thing. Next start-up went fine, and then the third my headlight went out... I have little/no experience working on my own bike and hoped this install would go smooth but now I'm stuck. If anyone can give me some tips or finding the short, or even advice on redoing my entire wiring I would greatly appreciate any help.

Aug 5, 2012 | 09:14 AM

run1fsr

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Joined: Oct 2007

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From: USA

Sounds like you have something shorted to ground. Did you disassemble the switches or cut the control wiring to route through your bars?

Aug 5, 2012 | 10:12 AM

Gpsjr10

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From: Elyria, OH

First question is: Are your new bars dimpled or drilled to allow the wiring to pass through the clamp and into the switch housing without being pinched?

Aug 5, 2012 | 03:21 PM

StayPuft

Thread Starter

1st Gear

Joined: Aug 2012

Posts: 5

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From: Washington

The bars are dimpled to allow the wiring from the controls space so didn't have to cut any of the wiring, I replaced the second blown fuse but am worried this is going to lead to further/more serious issues.

Aug 5, 2012 | 05:22 PM

run1fsr

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Joined: Oct 2007

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From: USA

So the bike starts and runs fine with a blown headlight fuse? Sounds like that's the problem circuit.

Aug 5, 2012 | 10:12 PM

Gpsjr10

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Joined: Jun 2007

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From: Elyria, OH

Somewhere a wire is probably pinched. If the headlight circuit is giving you trouble, open up the left switch housing and see if something is shorted to ground.

Aug 10, 2012 | 05:26 PM

StayPuft

Thread Starter

1st Gear

Joined: Aug 2012

Posts: 5

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From: Washington

Thanks for the help I took off both controls and wrapped each wire individually where there was a "splice?" and have been good since then. I think it was shorted to ground as you guys stated. Thanks again for the tips!!!