HarleyTechTalk

Tryin to help out a bro here,ya, I know its not a Harley but jus tryin to help him out.
Bike keeps tripping out what seems to be a breaker but its coming from a black box under the dash. He does not have a manual and trying to get one has proven to be a total loss since they filed and went under.

any help at all appreciated fellas, dont want to tear into to it without any info at all.

You are probably going to have to remove the dash and tank and check the wiring for a short, could even be in the handle bar switches. when you doing that you could draw up your own wiring diagram. The wires should have some sort of color code. Start with the circuit that breaker (the one that trips) protects.

PLan on that Friday, once I remove the middle connection on the dash switch the breaker(not sure which one yet) does not click, the bike will start if you press the start button the turn on the dash switch but it will die as soon as it clicks, Ignition is a Compufire Elite 1, as soon as I hook up the middle connection to the dash switch it will click right off.

Replaced the breaker today all was well until I started to put the handlebar controls back on,then the breaker tripped out. When to check for bad wires non the throttle side and found the front brake hose very hot as well as one on the throttle cables, used the meter and found that the bars had 10 volts running through them, with everything off the bars that has stopped, breaker does not trip out, no bad wires to be seen, also the brake light does not work, was thinking that the rear brake switch might be stuck open or something making the front brake switch heat up although it and the wires look fine, will be checking the rear fender area Saturday but fell free to chime in on this, to be honest, I am kinda lost on this one.

First thing that jumped to mind is that something is trying to find a ground. Try running a jumper wire from the battery ground to the front end...electrical gremlins can be elusive or very simple, cant hurt to try...

Thanks Warhorse, will try that, I did notice that there was not a ground from the frame to the front end.I amalso going to check the rear brake switch, it might be grounding out, but will have to wait until later, way to hot out now to mess with it.

Check the headlamp plug for a loss of ground connection.

All lights are working with exception of the brake light,didnt work on it today but will hit it again Sunday.

Check the wire bundle that runs along the "neck" for wire's that have rubbed through their insulation, or might even be broken.
"Jumper" wires run to each system, bypassing the wire harness can sometimes reveal the problem too.

It was the front brake switch that was causing the problem, disconnected it and all problems disappered, sure did cause a lot of headaches though, lol