Keep blowing P&A fuse. Have tried to isolate by disconnecting things but it keeps happening. Went 350 miles this week before it happened again. I almost thought I had isolated it. Was wondering if anyone has seen this caused by dirty, rusty ground connector. My brother thought it could be bad rectifier, but I think that would lead to more serious problems. The bike runs fine, just loose speedometer, turn signals and brake lights. Have disconnected accessory power connector only, after removing all accessories.

 

When that fuse blows sproradically, 90% of the time it's a wiring issue on your handlebars. If you've had the grip clamps off, you may have a pinched wire. If you haven't, you may have some insulation that's rubbed away somewhere.

 

I'll take your word for it since that's one of the areas I have not really probed. Never had anything off on the bars, but with 60K on the bike, could be.

Handlebar wires and cables have always freaked me out for some reason, even though stuff like working in the cam chest or primary don't scare me at all.

 

a rusty ground connector will NOT cause a fuse to blow, but it may make gauges act up and the lights to be dim.....I agree with sharknose about the handlebars being a likely problem area...also wires inside of the fenders and anywhere they get bent regularly like the steering neck area..

 

Agree. Rust increases resistance, not current. Something is shorting to ground. Take particular attention to what happens immediately before the fuse blows. Whatever circuit tries to activate is suspect.
Believe it or not, HD has a 'wiggle' test in the electrical diagnostics manual. Don't laugh, it works.

 

...and that increased resistance can blow a fuse or a breaker.

If this uses a conventional fuse, look at it:

A "sagged" fuse material indicates overload

A "splattered" or "sooty" indicates a short circuit.

1st day of 9th grade electricity class.

If you have a bunch of rusty connections, clean them up. A "nick-sander" from the auto body section at the auto parts store is a little fiberglass brush that works great. follow up with a contact cleaner and die-electric grease

Mike