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I have an '08 FLHX that has an issue with the headlights shorting out and blowing the fuse. I installed an LED headlight and passing lights about 8 months ago and everything has been fine. Just came off of a 1700 mi trip with no issues, thankfully. Went to ride yesterday and that's when I realized the headlights were out.
I put a new fuse in, started it up and watch the headlights as it idled. They flickered for a bit and then went out. Now as soon as I turn the ignition on it blows the fuse. I must have a short somewhere. I tried it without the headlight installed and it does the same thing.
Here's my question. When I check for ground on the three wires at the headlight connector I get ground continuity on the yellow wire. That's the low beam wire. Pretty sure I should not have a path to ground on that wire, right? The high beam wire, (white) does not.
If you remove the lamp and the fault persists then it is in the wiring. It looks like you have worked that out.
Go to the connector at the other end of the wire and remove it to isolate that small piece of wiring. Now using an ohmmeter check for shorts.
With the pins removed from a connector I have been able to pull them out of the conduit / sleeving. You might do the same to check for breaks in the insulation.
the headlight wire runs over the fairing stabilizer and chaffs barley with mileage. pull the outer fairing off and have a look. myself and my buds, all with over 80k have had this problem. reroute and electrical tape will fix it
God news bad news. The wires from the headlight connector go right into the main wire loom. Per the diagram it goes to the switch panel and the handlebar switch. I removed the switch panel and tested and the short was still there. Then removed the connector to the handlebar switch and it was gone. Plugged it back in, and it was still gone. Not sure what I did. I didn't find any evidence of a short. Will put a new fuse in and the headlights and see what happens.
Even if the fuse doesn`t blow, it doesn`t mean the problem is gone...
If the fuse was blowing, no matter what position the headlight switch was in (hi or low beam), it is telling you that the short is somewhere before the switch.
The issue could be anywhere between the headlamp fuse and the switch in the handlebar control, but it is most likely inside the fairing.
Pull the front of the fairing off and look carefully at the harnesses coming into the fairing on the left side of the bike.
Last edited by Dan89FLSTC; May 16, 2021 at 10:00 AM.
1plumr1 and Dan89 were correct. The low beam wire was chaffed on the fairing support. It was just barely visible but I was able to spot it with a flashlight. And I was able to confirm it with the multimeter. It was the section of wire between the headlight connector and the handlebar switch connector. That explains why reseating the handlebar connector "fixed" it. It just moved it off of the support temporarily.
Thanks for the help!! And yes, I need to take care of that white wire too. That was an old accessory I removed while I had the fairing off.
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Troubleshooting a shorted headlight
