[lwedwards]

I have an 02 Ultra, just did the Stage II buildup, after a couple of days it starting blowing the light fuse when I start it up. Orginally it was during a ride to work about half way there it blew the first fuse. I replace it with a 15amp fuse which is what it said it should be, as soon as I hit the starter it blew. Change to a 20amp and it started the first time no problem, the second time it blew. Any ideals??

[ironhorse]

first I'm taking it that it started after the stage 2 so I would start chasing wires to any thing remotely touched during the upgrade,then start at the fuse panel and make sure there are no pinched wires and that they are all correct, thats about 4 feet in either direction and you will find your short. somthing pinched a wire, is hooked up wrong, or you have moved some wire that was rubbing through, to a spot to finallize the problem. get out your multimeter and ohm out the circut (no power though). if your really brave (I don't recomend this to to the meek) build a smoker wire. I am sure though that a little patience and observance you will be able to see your problem first.

[00 wildglide]

Did you remove the outer fairing ?The headlamp pig-tail lead might have touched/chaffed its insulation through to ground.I would recommend the repair manual elect. schematic for that circuit & see how it routes in relation to the areas you worked near.You should not "up" the amp size for a short circuit problem,you can cause wires to get hot & burn.You can purchase a self reset circuit breaker from "RADIO-SHACK" for a few dollars during your diagnosis.A wiggle test via tugging on harness sections while the fuse/breaker is good can also help in chasing the affected "short to ground" condition.
**note: sometimes wires can "short to ground" inside their wrapped harnesses against another wire.
It may be nerve racking,but take some time & you will find it.Good luck! 00 wildglide

[chucktx]

you said you did the stage 11 buildup....would you give specifics on what you did?? i guessing you replaced the module. that is where i would look forthe problem,,,,you may have pinched a tail light/running light wire. we are all guessing. let us know what you did, maybe we can help you better!!

[lwedwards]

I didn't replace the module, I have a Fuel Pax which has been installed for a little over a year when I replace the pipes. I have been checking the wiring and yesterday after work I replace the fuses, turned it on and the light worked as soon as I got on the bike and set down it blew. Now when I change the fuse and turn it on it blows. So I think it is in one of the harnesses that runs under the seat just have to remove the covers and find which one it is. Thanks to everyone that replied.

[lwedwards]

I forgot to add I replace the jugs and piston's and installed the screamin eagle 203 cams. I left the engine in the bike and did the upgrade. I rode the bike for a couple of days before the first fuses blew. I normally ride it to work every day unless it is raining which doesn't happen much here.

[cowboy]

you had to pull your seat & tank , when you set down your weight will transfer over a bigger then just your back side , so it could be under the seat or tank might be something as a pinched wire

[chucktx]

you are in the right area....seat/tank area. all it is going to take now is some time to figure out which wire is pinched....good luck and let us know what ya find!!

[VYBR8ER]

Is your bike lowered? If so, check the wiring under your rear fender. The tire can rub through the rubber channel and wear through the wiring and cause shorts. Also a common place for the FLT line to have problems is where the wire bundle comes up under the fairing and is tie wrapped to the support frome of the fairing. Check for chaffing against the support.

[lwedwards]

Pull tank off last night and noticed that where I had the crome neck covers added one of the wire bundles was massed up and have a deep crease in it. Pull the covers and checked the wires and did not see any broken. Took the front of the fairing and started checking wires there. I checked the headlight connector and had continuity between all three connectors, don't think this should happen. I then started disconnecting harnesses back to the main harness, I installed a new fuse and turned it on and it didn't blow. I then reconnected everything and now there is continuity between only two wires and the the fuse is still good. Got me confussed.

[hotroadking]

You basically changed the harness location even a little and it probably moved the problem enough to keep it from blowing.

When it blows you have just sat on the bike which means the movement of the suspension is pulling on something.

Could have been a loose connection, or a wire that is slightly cut that opens when you sit down.

Good luck.

[ironhorse]

check in the deep crease area and every where you moved the harness during that time it will be there. it will only take a strand to short and blow a fuse. flex the wires with the power on and when it blows it will be in that area.

[lwedwards]

Finally had enough and took it to the dealer, should have done this to start with according to the better half. Problem front fender light wire shorting out. Took them about 20 minutes to figure it out. Thanks to everyone who replyed. Hope I can help out in the future.

[chucktx]

wow, 9 times out of 10 when a problem arrises...it is usually near or at the location of the last repair.....glad ya got it handled.....and thanks for letting us know what the problem was!

[cowboy]

wow I guess it did'nt look like a duck after all , but it must have been started to go bad about the same time you did all the enging work