Dam Springer

She keeps blowing the lighting fuse and have had all the wires apart, nothing. Does not do it all the time but never know when. I hate intermittent problems. Rode home in pitch black one night, good thing there was a car behind me to light the way. Couldn't even see to pull the seat and find the fuse at the tavern.

Did find the main switch where the red/black wire connects in the connector the connector was melted and burnt.
Interesting why it did that nothing loose. Cut the wires and picked up a new switch connector and new terminals. Something grounding somewhere. :gah:

But I'll eventually find it.

None seen so far going to pull the wire out of the headlight pigtail and check it next.

Mine did that, the sucker went through 4 main switches,
never found anything grounding, but it will get super hot.

They redesigned the switch, and the plastic connector

get the upgraded one, don't worry about the key
or waiting on a replacement that's keyed I can walk
you how to swap your old key barrel to the new switch.

As for the lights, I've had that as well, apparently a softail thing.

If you pull the tank the light harness is on the left side
follow it back, check the ground in the bucket, and don't run
a 100 watt bulb in it..

My head light is the 55/45 bulb. Got the tank pulled and the wiring exposed but still nothing. Did find two things the switch connector burnt and the friggen batter hot cable was a bit loose at the battery. :gah:

does the black connector at the main switch push on only.
does it have a tab for alignment and a retention clip or just push on.

What happens is the wire harness slips a bit and then it arcs and heats
up and melts the wire end connector.

You probably found the wires fried and hard as concrete up by
the ends, cut out the bad bits, get new crimp on connectors
and clean and crimp on new ones.

Get the new connector and the new switch that accepts the
new connector and keeps it from slipping.

When you remove the dash and reinstall it can move that's
why they upgraded it..

Yep, it's the kind of connector that just pushes on and only goes on one way. I cut it back to good wire and installed new new connectors. After I crimped the new connectors on I also soldered them in place. Fits good and snug now. I'll look into a new switch. Wouldn't mind picking up a whole new console that has the new speedometer and a tach built into it.

Mine is a 2001 so the newest one wont work.

Well, Josh I tore it all apart, rewired the headlight with new wiring down into the loom. Took the tank off checked wiring everywhere. Put it all back together and today was the first day I could or wanted to ride it where it was not freezing cold outside or raining so hard yea needed pontoons or outriggers.
I put 40 miles on it, all back roads where it would be not real smooth pavement. Wanted to put her through the hoops so to speak. Well, the headlight is still working and OLBill and I might go for a ride tomorrow. Gonna be clear and 50 out so sounds good and think I'll take the Springer tomorrow. Hope it works.

Well if you go back and read it from the beginning I had replaced the headlight with a used one when all this started happening. I also found a bad main switch and replaced it. So the only way to find out if its working is to ride it.

My guess is the wires overheated and the switch was going bad

As to the light it could have been something loose, it might be
a pin in one of the connectors to the headlight under the tank
on the left side wasn't all the way in the connector or totally
connected to main harness, close enough to work most of the time
but a little bump or vibration and pop off she goes...

Well we stopped for lunch in Silverton OR and the light is still on. Olbill said it is now bright white. Happy camper

Left Silverton and rode back home. Did a 124 miles on the bike and the headlight is working great. So it may have been the main switch or a combination of a loose wire or connector. But anyway its seems to be working. Even throw it was 40 starting out I didn't connect up any heated gear, didn't want to over load the system.

Even throw it was 40 starting out I didn't connect up any heated gear, didn't want to over load the system.
trying to be a real rider now :roflmao: no elec gear whats the west coast coming to