Suggestions on electrical problem?

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Dec 9, 2011 | 09:23 AM

eathomps

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Suggestions on electrical problem?

2002 FLTRI. Back in late July/early August my wife informed me that my headlights were out. Checked and found blown fuse. Replaced it and everything seemed good; figured after almost 10 years it finally had enough. Fast forward to this morning, I'm headed to work and come to a stop sign. State trooper going the other way stops as he crosses the intersection and informs me that my headlights are out. So it looks like I have an intermittant short somewhere in the lighting system.

Anyone aware of any known problem areas I should look first or helpful tips to help me find it. I truly hate electrical problems, especially the ones that don't stay broken long enough to find.

TIA

Dec 9, 2011 | 09:26 AM

'05Train

Ultimate HDF Member

Joined: May 2008

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From: 'Noke, VA

Chances are with a 2002 you've got a wire that's rubbed through and is grounding on the frame. It's a PITA, but you kind of have to pull the fairing and start tracing the wires back.

Dec 9, 2011 | 09:53 AM

FLPostman

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Joined: Jan 2011

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From: Leesburg, FL

Electrical problem

+1
What he said..Sounds like a dead short to me too. And yes- its a Pain in the *&^ to find. I feel for ya..

Postman

Dec 9, 2011 | 10:15 AM

Dailydriver06

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Joined: Nov 2011

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From: Wilmington, NC

Look at a wiring diagram and trace the wires that are common to the affected functions.Common places to check for shorts...Behind outter fairing, under seat, between rear fender and tire. Good Luck!

Dec 9, 2011 | 11:00 AM

journeyman

Road Master

Joined: Mar 2010

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From: SE Wisconsin

I would start with the wire loom at the neck, that area sees a lot of strain. turn the light on and grab hold of the wire loom and wiggle while watching for the headlight to flicker.

Dec 9, 2011 | 12:32 PM

mkguitar

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Joined: Sep 2010

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From: Phoenix '53, '88, '09 Big Twins

if you have a fuse that you can see:

black and splattered means short circuit ( rubbed wire etc)

sagged and parted fuse material means overloaded ( poor connection causing over load).

physically check the wiring- look at the headlight connector block for deforming or signs of heat damage

Mike

Dec 10, 2011 | 09:46 PM

eathomps

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Thanks to all who offered advise. This is one of the problems that I'll never really know if I fixed, but will eventually know if I didn't. I put the bike on the pipe lift, replaced fues and started. Tried all I could think of to blow fuse with no luck. Removed fairing and found places on light wires that were pinched and insulation cut. So I repaired those (in a somewhat overkill manner) and put back together. Time will tell if I did't get it fixed. Going to spend a few hours after church tomorrow on some less pleasant roads to see if I can get it to blow. If not I'll just be extra careful to check the lights before I roll off.