sparks shooting from underneath ignition switch on fuel tank
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Stage III
Joined: Nov 2012
Posts: 3
Likes: 0
From: USA
sparks shooting from underneath ignition switch on fuel tank
my 87 sportster XLH883 hugger's previous owner replaced the stock tank with a dyna fuel tank (speedometer and ignition switch mounted on tank). it looks great but is rife with problems. the latest issue is as follows:
when i move the switch (clockwise) towards the "on" position (9 o'clock) sparks begin to shoot up from underneath the chrome ***. i hear clicking as well. sounds like the battery engaging, quick flicker of the head lamp, but the light doesn't stay on. ...won't turn over. i just hear the head and rear lights (i think) clicking... as i turn the switch back towards the "off position" i get shooting sparks again. ...in addition the **** is sticking and difficult to turn.
lastly, i took the casing off of the tank to see if there are any loose wires on the ignition switch. ...everything appeared to be connected.
any suggestions?
when i move the switch (clockwise) towards the "on" position (9 o'clock) sparks begin to shoot up from underneath the chrome ***. i hear clicking as well. sounds like the battery engaging, quick flicker of the head lamp, but the light doesn't stay on. ...won't turn over. i just hear the head and rear lights (i think) clicking... as i turn the switch back towards the "off position" i get shooting sparks again. ...in addition the **** is sticking and difficult to turn.
lastly, i took the casing off of the tank to see if there are any loose wires on the ignition switch. ...everything appeared to be connected.
any suggestions?
Club Member
Joined: Feb 2007
Posts: 16,320
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From: Boynton Beach, FloriDuh
Do you know someone that's good with working on electrical or electronic equipment?
Since the wiring is not stock, and no one that can't see the bike is going to have any idea what someone else did when wired the custom tank and switches, it sounds to me like you need somebody that understands ignition wiring and can chase out the circuit with a meter.
Sorry, I know that's not much help, but diagnosing someone else's custom wiring job over the internet, is a bit of a stretch.
Since the wiring is not stock, and no one that can't see the bike is going to have any idea what someone else did when wired the custom tank and switches, it sounds to me like you need somebody that understands ignition wiring and can chase out the circuit with a meter.
Sorry, I know that's not much help, but diagnosing someone else's custom wiring job over the internet, is a bit of a stretch.
Thread Starter
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Stage III
Joined: Nov 2012
Posts: 3
Likes: 0
From: USA
Thanks for your advice. You're right, I probably need to take the bike to someone who knows electrical. I think I am just going to have my bike serviced at HD tomorrow. Winter is near, so every day without snow and ice is a priceless riding day.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,897
From: Bedford UK
We must assume that it didn't spark when the current tank was originally installed! So something has gone wrong recently, although that may be as result of a poor quality installation. It could be a duff switch, or a short-circuit caused by something like a chafed wire.
If you want to tackle this yourself, disconnect the battery (I would remove it from the bike), then remove the tank, very carefully! You may find something obvious, like a bared wire, even a loose end, in which case you can fix it yourself.
If however you can find nothing like that, then as suggested find an electrical expert. I would steer clear of a Harley dealer, partly because many of them won't know that Harleys built bikes as long ago as that, but also unusual stuff is best trusted to a friendly indy who knows how to use a multi-meter!
If you want to tackle this yourself, disconnect the battery (I would remove it from the bike), then remove the tank, very carefully! You may find something obvious, like a bared wire, even a loose end, in which case you can fix it yourself.
If however you can find nothing like that, then as suggested find an electrical expert. I would steer clear of a Harley dealer, partly because many of them won't know that Harleys built bikes as long ago as that, but also unusual stuff is best trusted to a friendly indy who knows how to use a multi-meter!
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We must assume that it didn't spark when the current tank was originally installed! So something has gone wrong recently, although that may be as result of a poor quality installation. It could be a duff switch, or a short-circuit caused by something like a chafed wire.
If you want to tackle this yourself, disconnect the battery (I would remove it from the bike), then remove the tank, very carefully! You may find something obvious, like a bared wire, even a loose end, in which case you can fix it yourself.
If however you can find nothing like that, then as suggested find an electrical expert. I would steer clear of a Harley dealer, partly because many of them won't know that Harleys built bikes as long ago as that, but also unusual stuff is best trusted to a friendly indy who knows how to use a multi-meter!
If you want to tackle this yourself, disconnect the battery (I would remove it from the bike), then remove the tank, very carefully! You may find something obvious, like a bared wire, even a loose end, in which case you can fix it yourself.
If however you can find nothing like that, then as suggested find an electrical expert. I would steer clear of a Harley dealer, partly because many of them won't know that Harleys built bikes as long ago as that, but also unusual stuff is best trusted to a friendly indy who knows how to use a multi-meter!
If you do not see burn marks from the sparks after removing the console, the issue is most likely inside the switch itself. Remove it from the console and try operating it, if you still get sparks, it is the switch.
What model tank and console, post pics.
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Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,897
From: Bedford UK
This is a non-stock installation. I only suggest removing the tank to get best sight of what is going on in the wiring to the switch. The switch may be sparking because there is a short-circuit in the wiring to it. Who knows what horrors there may be under it?!
Good point, but start with the easy stuff first, if you don't see it, then dig deeper, removing a tank is much more work than removing a console.