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Fatboy electrical troubleshooting

Discussion in 'Motorcycle Tech Talk' started by slyman777, Aug 9, 2010.

  1. slyman777

    slyman777 New Member

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    :wtf:Alright guys, here's the story...I hit a deer on my 2003 Fatboy back in June and am trying to piece it back together a lil bit at a time. I started with the handlebars cause I knew I could ride it if I fixed the bars. Needless to say, I got a great deal on the bars and decided to internally wire them myself. All went relatively smooth, keepin in mind everything is bent, and I took it up the car wash to uncover some more chrome rash. That's right, broken leg and all i rode it up there with no problems. On the way home it cut out, but I just assumed i got something wet, though I was very cautious. Took a few little trips around town and felt like I could go for a highway cruise

    5 miles down the road the bike cut out again, this time it will not snap out of it and it came home a trailer...after checking fuses, i found 3 sometimes 4 fuses keep blowing as soon as i turn on the ignition: the accessory fuse, the ignition fuse, the lights fuse, and sometimes the guage fuse.

    Heres the question already, is the wire short in the handlebars i wired, or is there a chance i broke something loose when i crashed? I am just not sure where to start looking and don't wanna do those bars again and find it was something else. Thanks already for all your help
  2. hotroadking

    hotroadking Super Moderator Staff Member

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    either could be it...

    Let it dry out, you have a short somewhere and wires are grounding.

    When you ran the wires through the bars did you nick or cut any...

    I'd remove the dash and tank, inspect the wires, remove the
    rear wheel splash guard, look under the frame for a cut wire.

    With all the fuses going check the wire going from the Voltage regulator
    to the main breaker along the bottom of the frame...
  3. chucktx

    chucktx Moderator Staff Member

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    agree!!!!! and it will probably end up being a PIA!!!
  4. slyman777

    slyman777 New Member

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    Thanks guys...the fun starts today...supposed to have a heat index of 110-115 today, so we'll see how long I stay at it with my gimped up leg. I hope it is something out in the open, but I agree that it will probably be a PIA, but i thought that when i started this project
  5. hotroadking

    hotroadking Super Moderator Staff Member

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    Do you have a SM?

    If not get one, with you having to do a rebuild, it has
    all the things you need to know to take it apart and
    put it back together properly, tq values, sequences
    etc.

    ALso pop a few bucks for the parts manual, it
    will allow you to make a list of what you need,
    then, go online to Chicago Harley-Davidson Genuine Harley-Davidson Parts And Accessories. New and PreOwned Motorcycles 1-888-338-6868
    and order them all at 20% off, or call Jenni at www.tri-countryharleydavidson.com
    20% off there, put together a list and order it at one time

    Order the books their if you dealer wants 100% price...

    Oh and don't pressure wash the bike
    HD bearings don't like that, can futz up the wheel bearings...
    At least on the older ones, I wouldn't pressure wash it though...

    One other thing, now that it's home and dry, put in new
    fuses and see if it starts, if so, and it doesn't blow the fuses
    take a water hose without the spray handle and just soak the bike
    starting up front by the VR and work you way back along the frame
    on the right side (wires are there) in behind oil tank (wires all go there)
    moving up slowly until it dies or pops the fuse, at least then you'll
    know where to look.

    Typically though I find my problems
    are where I just finished working....
  6. slyman777

    slyman777 New Member

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    thanks...I took all the advice and started where i just rewired the handlebars because it was still popping fuses today after it dried. Everything was going a lot smoother the second time, but I am still having problems running my last set of wires for the "end of the handlebar blinkers", just too many wires stuck in there.


    While pulling apart my work, I did find a couple/three small nicks in the insultation, so whether or not it is the problem I am glad I rechecked em...hopefully that's all it was, but we will see if I ever get the last wires ran...hopefully tomorrow's my lucky day, cause today was frustrating

    thanks again for all the advice...pretty sure the water hose working back was the first time I heard of troubleshooting that way, but I love it...If my wires weren't the faulty problem, I am going that avenue next
  7. hotroadking

    hotroadking Super Moderator Staff Member

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    Used it to find that problem on a bike
    where it would pop and backfire like crazy
    but only when the guy got caught in the rain.

    We looked everywhere and couldn't find
    any bad wires or connections.

    When dry it ran great...

    Took a low pressure water hose to it
    and moved up, when I hit the front cyl
    plug wire it went nuts, popping backfired
    and arc'd the plug electricity out the side of the
    wire to the head...

    Easily repeated...

    Checked the wire and it had a nice smooth
    tiny slit in it.. No way you'd see it or feel
    it running your hands over it but
    if you bent the wire in that specific point
    you would see the cut...

    New plug wires and it was fixed...
  8. chucktx

    chucktx Moderator Staff Member

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    ya may have found it if ya ran a wet finger over the wire!!!!!!!!!:D
  9. hotroadking

    hotroadking Super Moderator Staff Member

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    yeah like that was the first idea....
    then I couldn't convince him to do it...
  10. slyman777

    slyman777 New Member

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    Well, I started over at the beginning by pulling all the wires out and checking them closely, sure enough, a few small nics and found a pretty serious pinch due to the aftermarket bars and the pre drilled holes. I just rebored the holes, redid everything I did the first time, only with a little more knowledge and speed, and voila everything works. It is still probably not up to a professional's standards, and I still havent put on blinkers yet, but everything else works, so everyone can drink one on me.

    On another note, I still need replacement 100th anniversary tins for a 2003 FLSTFi. Originally it is silver over black, but i would consider solid black, just not the blue

    If anyone ha ever had to mess with Harley and their 100th anniversary stripe, you know how impossible it is. You have to turn in your old badges in order to even order new tins, not to mention pay for them up front and wait until they want to get around to special mixing the paint and doing it...think it took like 2- 3 months last time...so if anyone knows anyone that went custom with their's before they wrecked em up...send em my way...I now know I HATE WHITETAIL DEER

    on another note....Rode it about 120 miles today...stiffened up the leg/ankle quite a bit but it was so worth it...much needed stress relief and a lil self satisfaction that I can now ride until I can afford to pay for the rest of the mess...
  11. chucktx

    chucktx Moderator Staff Member

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    glad ya were able to get into the wind!!!!!! stay safe and have fun!
  12. cowboy

    cowboy Moderator Staff Member

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    good the here you back up & running, Try all the locla Indy shop's in your area ,& ask around , then C list & ebay
  13. hotroadking

    hotroadking Super Moderator Staff Member

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