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I am going to give some details on what I did to the bike so hopefully you guys can let me know where to start. I am at work and did not yet look for the problem.
I am blowing headlight fuses, 3 so far. The bike is a 2006 Road King Classic. I just replaced the raisers because one of the top clamp bolt holes was stripped, I noticed that there was a wire attached to the raiser bolt so I made sure I returned it to where I took it off. After that I had no problems. Next I either lost or broke the front motor mount bolts after hitting a pothole. They are the 2 under the oil filter. I replaced those and changed the oil while I was at it. I don't remember banging or doing any damage in anyway to the voltage regulator. Anyway, replaced the motor mount bolts, changed the oil and buttoned it all back together. Took it out for a short run, no problems as far as I could tell but it was daylight at the time. Went to take the bike to work that night, no headlights. Next day, found the fuse had blown, replaced it. All is right with the world. That was about 3 days ago. Tonight I took the bike to work, got about a half hour into the ride and poof...no lights, pulled over replaced the fuse again, lights work, continue on my way, got about 1/2 a mile and poof...no lights and no more fuses. Rode the rest of the way in the dark. Taillights work, turn signals work, just the headlights and driving lights are out.
I have had a problem with the negative battery cable coming loose, but that has been going on for years and hasn't happened recently. Any help on where to start looking would be appreciated.
It does sound like a pinched wire or maybe a wire that has been vibrating against something until it wore a bare spot on the insulation and created a short. Maybe check the plug that your headlight bulb plugs into. Those can burn out over time and ultimately short out causing blown fuses. You can replace those by going to an auto parts house instead of your Harley dealer. Much cheaper and an easy fix with solder and heat shrink tubing. Usually 3 wires as I recall.
I think I found it. It looks like I pinched the wires between the risers and the Street Slammer riser cover. I moved then and retaped them. I guess I will find out tonight if they stay on. Thanks for the help.
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