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Author Topic: Short?  (Read 3998 times)

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Tom149

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Short?
« on: May 30, 2011, 05:19:37 PM »

I am having a problem and wondered if you forum members might have some thoughts about it. While riding my 06’ FLHTCUSE today all of my small gauges and small gauge lights stopped working. In addition, the speedo and tach stopped working, but their lights continued to work. The security system lamp also came on and stayed on. I pulled the maxi fuse and fuse box cover and the number 4 fuse was blown. I replaced it with a new 15A fuse and that fixed the problems for a short time, but it blew again when I started the bike. I replaced it again and this time it blew when I turned the ignition to the ignition position. Any help would be greatly appreciated.

Tom149
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Tom

Cowboy2

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Re: Short?
« Reply #1 on: May 31, 2011, 12:19:22 AM »

Tom, that sux...

To state the obvious, you have a short somewhere.  FIRST, do step one: Look for a pinched wire, by tracing the circuit from the fuse board up through the bike.  It is hopefully a simple pinch or worn through insulation and a visible short you can find....  I give this a high likelyhood...  If not then you have to try and isolate it to one of the components involted by the method of one by one hookup until the fuse blows.  In the course of both of these, I would give it a 95% chance of finding it.  Use good lights, trace it out carefully, look closely..

If you are handy, step two is more involved and you are going to have to do what the HD Shop would do and I think you need to pull the fairing off.   Look at all the gauges involved on the that power leg and try to find something vibrated through, worn insulation, pinched wire, something that would cause this short.  You might get lucky and find a visible fault, look closely, as the next step would be more involved again...

Failing that, the short could be internal, and this takes a step by step total isolation and hook up one by one.  What I mean is you need to isolate this power leg causing the problem, off of all the gauges involved at first..  Tape up the ends, and if the fuse does not blow with the bike idling then shut it off and hook them up one by one, starting the bike each time.   You do this to see if you have isolated it or that gauge is ok, then turn off the bike and hook up the next one...  The last hookup before the fuse blows will isolate it down to that one defective part if the short is internal and not visible.  This is a time consuming way to attack it, but you are saving the big Shop time costs.  In the course of this, you are likely to find the short. 

Good Luck, Cowboy in Australia
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Tom149

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Re: Short?
« Reply #2 on: May 31, 2011, 11:20:50 AM »

Thank You for your response Cowboy!
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Tom

Hugh Janis

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Re: Short?
« Reply #3 on: May 31, 2011, 11:40:39 AM »

Yeah, that's a good. I was going to recommend replacing the fuse with a paperclip and look for the source of the smoke when you turn the switch on.
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spydglide

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Re: Short?
« Reply #4 on: May 31, 2011, 12:24:16 PM »

Yeah, that's a good. I was going to recommend replacing the fuse with a paperclip and look for the source of the smoke when you turn the switch on.
well, hey.... :nixweiss:.......just another approach and much quicker also.  :-[  har.  spyder
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Tom149

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Re: Short?
« Reply #5 on: May 31, 2011, 02:29:48 PM »

Yeah, that's a good. I was going to recommend replacing the fuse with a paperclip and look for the source of the smoke when you turn the switch on.

Awesome ...... LOL  ;D
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Tom

Cowboy2

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Re: Short?
« Reply #6 on: May 31, 2011, 06:42:01 PM »

Yea, maybe you guys are right... I guess I should not try and help a Brother, and should just take a humorous poke at it..
Would save a lot of time, and be funnier than trying to help...  You Guys are on to something here.

 Is this the path we should all take?
Naw...  Funny, but I don't think so...  I will lend a hand to help a Brother when I can... I am far enough away in Australia that you can't throw rocks at me..      LOL............. LOL


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Hugh Janis

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Re: Short?
« Reply #7 on: June 01, 2011, 07:23:06 AM »

Yea, maybe you guys are right... I guess I should not try and help a Brother, and should just take a humorous poke at it..
Would save a lot of time, and be funnier than trying to help...  You Guys are on to something here.

 Is this the path we should all take?
Naw...  Funny, but I don't think so...  I will lend a hand to help a Brother when I can... I am far enough away in Australia that you can't throw rocks at me..      LOL............. LOL

It's cool.  He got the answer he wanted in the 1st post and an answer he didn't in the 4th post......

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HogBreath

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Re: Short?
« Reply #8 on: June 01, 2011, 10:58:34 AM »

Yeah, that's a good. I was going to recommend replacing the fuse with a paperclip and look for the source of the smoke when you turn the switch on.

Adding to this, if all the smoke comes out, you can buy a new can of smoke at any Napa store. The gauges will NOT operate without smoke.
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Unbalanced

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Re: Short?
« Reply #9 on: June 01, 2011, 11:18:11 AM »

I would check for a short in/under the left hand grip area run/stop.  Maybe a pinched wire under the switch housing or the wire in the switch housing might be loose or such. 
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Harleypingman

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Re: Short?
« Reply #10 on: June 01, 2011, 01:55:31 PM »

If you don't already have them, buy the HD Touring model Service Manual and the CVO Ultra supplement for 2006 model year.  You'll have the wiring diagrams with the color codes for the wiring at your fingertips which makes tracing the problem much easier IMO.

Hope you find the problem soon.

Carl
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Tom149

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Re: Short?
« Reply #11 on: June 01, 2011, 02:40:13 PM »

If you don't already have them, buy the HD Touring model Service Manual and the CVO Ultra supplement for 2006 model year.  You'll have the wiring diagrams with the color codes for the wiring at your fingertips which makes tracing the problem much easier IMO.

Hope you find the problem soon.

Carl

Thanks to all .... I have both manuals and it appears to be a short either at the Keyswitch Ign Relay or at the Interconnect Harness. The heavy gauge (R/BK) wire that comes out of the #4 (15A) fuse block, which continues to blow, terminates at the Keyswitch Ignition Relay and the (O) wire terminates at Interconnect Harness (1A) (BK). Time to pull the outer fairing and do some investigating.

Tom
« Last Edit: June 01, 2011, 05:23:32 PM by Tom149 »
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Cowboy2

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Re: Short?
« Reply #12 on: June 01, 2011, 05:13:42 PM »

Hang in there Tom,

When you get discouraged, ask what the Shop rates are at your local HD, THAT is what you are working for on your spare time...  :2vrolijk_21:  When the fairing is off, have a careful look over all the components affected.

Keep tracing, powerful light, careful look, and with a little luck you will find an obvious vibration wear point or pinch that you can spot.  If it blows a 15 amp fuse, you should even see a little blackened spot at the short site, that will be a dead give away.  I think it is extremely likely to be a mechanical fault thing where the vibration or pinch has worn through insulation... I build Bushtrackers in Australia, the number one off road trailer, and we routinely have $30,000 to $40,000 in electronics and electrical gear and the corrugations of the Outback, rarely cause problems like this because we bundle carefully. 

When it is all said and done, with the fairing still off, if it was chafe or vibration or pinch failure...  Myself I would insure it does not happen again by carefully bundling with small electrical ties, and maybe put on the automotive style split black ribbed conduit over anything exposed...  Good luck with it... !!! :2vrolijk_21:
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Tom149

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Re: Short?
« Reply #13 on: June 01, 2011, 05:23:56 PM »

Hang in there Tom,

When you get discouraged, ask what the Shop rates are at your local HD, THAT is what you are working for on your spare time...  :2vrolijk_21:  When the fairing is off, have a careful look over all the components affected.

Keep tracing, powerful light, careful look, and with a little luck you will find an obvious vibration wear point or pinch that you can spot.  If it blows a 15 amp fuse, you should even see a little blackened spot at the short site, that will be a dead give away.  I think it is extremely likely to be a mechanical fault thing where the vibration or pinch has worn through insulation... I build Bushtrackers in Australia, the number one off road trailer, and we routinely have $30,000 to $40,000 in electronics and electrical gear and the corrugations of the Outback, rarely cause problems like this because we bundle carefully.  

When it is all said and done, with the fairing still off, if it was chafe or vibration or pinch failure...  Myself I would insure it does not happen again by carefully bundling with small electrical ties, and maybe put on the automotive style split black ribbed conduit over anything exposed...  Good luck with it... !!! :2vrolijk_21:

Thank You Cowboy,

Tom
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Tom

kerb

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Re: Short?
« Reply #14 on: June 04, 2011, 11:29:37 PM »

Adding to this, if all the smoke comes out, you can buy a new can of smoke at any Napa store. The gauges will NOT operate without smoke.

I always thought the smoke was factory installed/
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