Electrical help needed.
 

I was out for a nice ride today, Doof waving and all. The ride suddenly ended about 11 miles from home. She just went dead. Speedo, lights, engine. The whole works. A friend came and picked me up, back home for the trailer. She's in the garage now. If I turn the switch to the run position, I can hear a click, like a circuit breaker tripping. In accessory position, everything is OK. It takes a couple of minutes for the breaker to reset. I've removed the battery, and attached a battery charger to the cables to rule out the battery. I get the same result with the charger. The click is towards the rear of the bike, but I'm not sure where the short could be. I'm stressed because Tuesday we were taking a 5 day, 4 state trip. I guess that's on hold now. I don't want to make this trip with her on a trailer, I'm not going to Sturgis.
Does anyone have any helpful hints where to start looking? Btw, our last stop was a car wash, but she fired right up, and took me about 15 miles before going dead. She's been in the garage about three hours, same effect.

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Sound like a loose positive battery terminal. Ask me how I know

It was tight when I removed the battery, and does the same thing on a charger with no battery.

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It didn't blow any fuses?

That concerns me a little.

Unplug all the connections under the seat.

Try to start.

Then plug in each connector, one at a time, with the key off.

Try to start each time.

See if that at least identifies one part of the loom.

If your TSSM is bad, I don't think you would get anything.

It almost has to be a module like the fuel pump module or the ignition module that causes the problem without blowing a fuse.

I suppose the ignition switch itself could use testing.

Electrical help needed.
 

First thing, PLEASE don't hook up the charger to it without a battery. This is really important!
Car battery chargers have a simplistic load-sensitive circuitry that REQUIRES the battery as a shunt in the circuit. With no battery the charger can put out excessive voltage and fry ECMs.
Weak or charged, just have a battery in the circuit.
Edit: the same issue exists with the bike's own charging system, never disconnect the battery to "test" a running bike or car.

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You said all was good in ACC mode but when you switch to IGN does it immediately shut down or do the lights stay on for a bit?


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Electrical help needed.
 

I say worn out ignition switch, short when in the run position tripping the breaker.

Immediately.

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I tried a different switch. Everything works. I plugged in the old one, everything works. I'm wondering if something got wet at the car wash and finally dried.

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Does it still have the POS 40A circuit breaker verses the 40A maxi fuse for thr main supply to the bike? Those get tired and won't stay closed, heat causes them to degrade.

I think HD changed to maxi main fuse around 2004 ? Can't recall?

That happened to me twice at the car wash. Once in Mississippi and once here. That was several years and many miles ago and it has never done it again.

Both times it did blow the TSSM fuse.

Was that still the same switch the key barrel pulled out of in the Walmart parking lot in Arkansas many moons ago?

Not that I laughed or anything.

No it wasn't, this was only about a year old. Everything seems fine, I'm going to replace the main circuit breaker just in case.

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This.
Put in the Maxi Fuse and problem went away.

http://images.tapatalk-cdn.com/15/08...7dde3bb0b6.jpg

I'm gonna go with moisture somewhere it shouldn't be. About 520 miles yesterday, and she never missed beat.

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