Any wiring gurus out there
Thread Starter
|
2nd Gear
Joined: Jul 2016
Posts: 6
Likes: 0
From: indiana
Any wiring gurus out there
Have 98 ultra. Have been blowing brake light fuse. While investigating this I turn handlebars and fuse blows. So I start looking into the fairing wiring. Notice the main 3 wire plug with 12 v incoming is hot to touch and coating is melted. These wires appear to feed the whole fairing system. They split into the ignition switch and guessing starter relay. If I unplug the main one I get 12 v but also continuity to ground. When I plug it back in I only get about 10.1v when ignition switch turned on. So safe to assume the short is in the switch or relay side? Also seems like the relay side gets hot faster than the actual incoming line. I have checked the other side all the way back to circuit breaker relay and fuse block with no noticeable bare spots or shorts. Thanks in advance
Cruiser
Joined: Jan 2014
Posts: 147
Likes: 61
From: Mulkeytown, IL
The problem may be the plug itself. A lot of resistance can develop over time through the pins. May be why the plug "melted" to begin with, and that you are seeing a two volt drop when connected. If you know how, do a voltage drop test across the connector from one side to the other. You may find your two volts.
OP,
Let's get down to details. " I turn the handlebars and the fuse blows" which way? Turning bars left blows fuse but not right? or either way? Have to turn bars all the way to blow fuse or only part way?
If Bike is solid, like locked in a chock or on a lift, so that bars don't move, can you turn it on and let it sit does the fuse eventually blow?
If it only happens when the bars move you have a touching problem. Wires are moving and making contact either with bare metal or another wire. It is possible that it is in the plug. Could be turning the bars is pulling on the wire which is pulling the pin out of the connector so that it is moving in and out of position causing a connection arc similar to when you hook up a battery charger on your car. It is also possible that it is somewhere making contact with another wire that is then causing an extra draw from something that wouldn't normally be turned on therefore overloading that circuit.
Or it is just touching metal causing a dead short to ground.
Pull the fairing cap, follow the wires. I would bet it is somewhere in the bundle running up to your right grip by the brake lever. That brake switch has power to it all the time on one side.
Let's get down to details. " I turn the handlebars and the fuse blows" which way? Turning bars left blows fuse but not right? or either way? Have to turn bars all the way to blow fuse or only part way?
If Bike is solid, like locked in a chock or on a lift, so that bars don't move, can you turn it on and let it sit does the fuse eventually blow?
If it only happens when the bars move you have a touching problem. Wires are moving and making contact either with bare metal or another wire. It is possible that it is in the plug. Could be turning the bars is pulling on the wire which is pulling the pin out of the connector so that it is moving in and out of position causing a connection arc similar to when you hook up a battery charger on your car. It is also possible that it is somewhere making contact with another wire that is then causing an extra draw from something that wouldn't normally be turned on therefore overloading that circuit.
Or it is just touching metal causing a dead short to ground.
Pull the fairing cap, follow the wires. I would bet it is somewhere in the bundle running up to your right grip by the brake lever. That brake switch has power to it all the time on one side.
Grand HDF Member
Joined: Mar 2010
Posts: 3,949
Likes: 150
From: South of Mordor
To add to cprheds post. It is your brake fuse that is blowing correct? That possible short, wire contact or possibly almost broken wire could be up at your handle bar switch housing if your wires are internally wired. You could have a pinch where the switch housing wire enters the handle bar. The motion when turning the bars could over time have put tention on the wire causing it to start to fray and then ground out on the bar.
Thread
Thread Starter
Forum
Replies
Last Post
DrPlastic
Touring Models
22
Sep 25, 2008 08:34 AM
