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[sponserv]

Have had a weird thing on my bike since new. Bike died outside of dealership during Biketoberfest. They took it in and called me the next day after replacing the ecm 15 amp fuse. I asked why did the fuse blow and got the "must have been a weak fuse" answer. Unacceptable but hard to argue.

Worked fine for about another 500 miles until today. Pulled up at a light and a huge puff of white electrical smoke comes out from under the tank and bike dies. All electrical accessories are good but bike won't run.

So I always carry spare fuses now so I check ecm fuse (blown) and replace. No luck. As soon as I go to start bike again the fuse blows.

 Just like last time. So I haul it back down to same dealership and drop it off. Tell them to call me when the really have it figured out.

Any ideas my friends?

[hd-dude]

Are you sure it was electrical smoke and not a back fire through the intake? If it was electrical smoke there will be burnt wires in the harness / cable tray under the tank.

[copout221]

I know I read about this exact same problem on this forum or HD Forums but I cannot remember what the problem was. I would try searching both forums.

[ESJ JESTER]

I cant help much but do know that fuse gets power from maxi-fuse and it supplies constant power to ecm AND supply power to the "system relay". once ignition switch is turned on now system relay supplies the same power to the fuel pump fuse and both injectors and coils!  if a new fuse is put in... the relay unplugged...and fuse blows...ecm bad or harness burned/bad. BUT if no blow  then re-install  relay and confirm fuse blow.  If it does then poss. bad coil pack,injectors(prob not) or burned/bad harness.  I am sure they will find it by following the smoke...   [smiley=nixweiss.gif]

[ESJ JESTER]

Further parusing of wiring diagram shows the front and rear acr's (auto compression releases) also recieve power from system relay..all on the same 15a ecm fuse.  I would venture to say they would be my suspected source of smoke/failure.  Hope you get positive resolution Sponserv with a more confident explanation.  

[djkak]

I cant help much but do know that fuse gets power from maxi-fuse and it supplies constant power to ecm AND supply power to the "system relay"......I am sure they will find it by following the smoke...   [smiley=nixweiss.gif]

It sounds like your intermittent problem has become a permanent one. Once the issue can be duplicated in the shop the resolution should be permanent as well.

I have always wondered how all of that smoke in the wiring makes the engine run; after you let the smoke out, the engine, she no run.

djkak

[ESJ JESTER]

   hay   sometime  the rubber....   she break   huh?    [smiley=huepfenlol2.gif]

boy theres lots of stored smoke in that fairing  too!!!

[napalm]

This is frustrating chit to happen.  My wife's '03 Road King used to quit while she was riding it....it did start back up....dealer replaced the Engine Control Sensor, according to the computer that is what was wrong.....since then it has been running fine.

Yours sounds like a different issue.  I here HD had problems with the 15 Amp Fuse you are talking about.

Tell 'em to get it right!!!!!!

napalm

[Rhino]

This MAY be or not another idea. When turning on ignition, I was told to always wait for the start sequence  (light) to extinguish before hitting the starter.  Any particular reason this might not allow the circuits to behave normally?

Rhino

[ultrafxr]

This MAY be or not another idea. When turning on ignition, I was told to always wait for the start sequence  (light) to extinguish before hitting the starter.  Any particular reason this might not allow the circuits to behave normally?

Rhino

That's just to make sure the fuel pump has had time to get pressure up.  Should not affect electrical circuits.

[sponserv]

And the winner is......drum roll please........ESJ Jester! Good job!

Got the bike back from the dealer today. It seems the front ACR (auto compression release) had shorted out. Service manager explained that the wring and fittings leading to the acr were fine and all crimps tight. However, the electronic portion of the acr is embedded in epoxy and it seems the metal part embedded in the epoxy shorted out against the tin edge of the unit. Not quite sure how something solidly emebedded in epoxy can drift over to the edge of its container to short but thats what they told me. I did not inspect the part. I was just thankful I wasn't replacing a complete wiring harness. So kids, if your ecm fuse blows and it happens when you are starting the bike or you have a large white puff of smoke emitted from directly under the tank...take a look at the ACR's. Now what kind of prize do we have for EJS Jester?

[Hoist!]

And the winner is......drum roll please........ESJ Jester! Good job!

Got the bike back from the dealer today. It seems the front ACR (auto compression release) had shorted out. Service manager explained that the wring and fittings leading to the acr were fine and all crimps tight. However, the electronic portion of the acr is embedded in epoxy and it seems the metal part embedded in the epoxy shorted out against the tin edge of the unit. Not quite sure how something solidly emebedded in epoxy can drift over to the edge of its container to short but thats what they told me. I did not inspect the part. I was just thankful I wasn't replacing a complete wiring harness. So kids, if your ecm fuse blows and it happens when you are starting the bike or you have a large white puff of smoke emitted from directly under the tank...take a look at the ACR's. Now what kind of prize do we have for EJS Jester?

How about a week's Room and Board during Bike Week! Hoist!  8-)

[ESJ JESTER]

How bout a week as the fitting room attendent in Victoria's dressing room...   shhhhhh   keep it a secret tho [smiley=xyxthumbs.gif]

[Hoist!]

How bout a week as the fitting room attendent in Victoria's dressing room...   shhhhhh   keep it a secret tho [smiley=xyxthumbs.gif]

Hey Gene , I saw sponserv's location. That's why I joked about the Daytona trip. But you da wiring man, huh? Good to know! Hoist!  8-)

[ESJ JESTER]

Thanks Hoist, I enjoy  diagonois and have many years of it behind me. it all depends on the accuracy of the problem description and available diagrams/design info.   the only way to increase the top cruise speed would be to increase its value in the  IC chip in the controller and that aint happining (i dont think) maybe hook a nitrous blaster to the horn button?  Actually when in cruise mode at 80+ I to get nervious by the time I am finished screwing with the phone or nav or some techno thing i am up someones t-pipe..as these B/O ones just cant stop!! ( that is unless the engine blows or something trivial  like that) [smiley=huepfenlol2.gif] [smiley=xyxthumbs.gif]