Wiring nightmares

Well I'm new to this forum and I'm experiencing some issues with my 2000 Cyclone. I will give a brief summary of what I'm dealing with.

Last fall I was riding my bike and my header cracked. No big deal right. So I started tearing into the bike to get the headers off and get welded up. Well this turned into me taking the gas tank off, the rear cowling, and other things I felt were in my way. I unhooked the circuit breaker as well as the negative battery cable from the frame. After the header was welded back up I attempted the assembly. Everything was going well until I got to the circuit breaker. Needless to say I couldn't figure out which wires went where. I was able to track down a manual that showed the correct wiring, but when wired correctly the circuit breaker keeps tripping. Upon a recommendation I ohmed the circuit breaker which shows that the breaker is in working order. Also when hooking the battery up I noticed that when the negative cable is hooked up and I touch the positive cable to the positive on the battery I'm getting sparks. So I am assuming that I have something grounding out that shouldn't be. I'm thinking it's the voltage regulator but I am not sure.

I apologize for the long story. I am running out of ideas at this point and I am left with a bike that is almost completely disassembled. Any suggestions are appreciated!!

Thanks in advance.

Where are you located?

I'm in northern Wisconsin.

I worked on my bike again last night. Basically I wanted to make sure I knew how to reassemble everything and in doing so I hooked the voltage regulator up but didn't mount it to the frame. For whatever reason the electrical was working. But when I mounted the regulator the same problems started again. I'm thinking about trying a new regulator?..

Sounds odd

I believe I'm heading in the right direction thinking the voltage regulator is the problem. I hooked the regulator up again with just the power lead and the circuit breaker was tripping. So I decided to remove the regulator and hook everything else up. Upon doing this I tested the female end of the power supply to the regulator and it tested out at 12.4 volts. So I have power to that point. I am going to try a new a regulator and see if this fixes my problem!

Fingers crossed!

One thing i can say is that the sparks are normal. Thats because the electric is jumping over to the positive and creating the connection. You ate just moving to slow and so you notice the sparks. Its just like if you were to take your pos terminal off of your battery on your car and slowly connect it back up. You will see sparks.

Finally!!! I went with my premonition and bought a used voltage regulator. Well that was the problem. Something must have been grounding out that shouldn't have been in my regulator. Now all I have to do is wire up the new integrated tail lights and I'll be ready for the road. Does anybody have any first hand knowledge on doing this? It seems like it should be pretty self explanatory.

Thanks for the help!!