My Bike DIED while driving. Any idea on identifying electrical SHORT?

[KC_Buell]

I was cruizing around 40 mph in the neighborhood and all of sudden bike shut down. Speeodometer is stuck on 40 MPH and RPM is stuck on 4,100, lost all power at the meter cluster. I check the "battery fuse" (the only 30 A fuse) and it was clearly blown. I went to replace it with the new one but it sparked as I was trying to put the new one in (FYI, I did this with the ignition key out). There is clearly a short somewhere but has anyone else experienced this before before I start to tear this baby down?

[KC_Buell]

I checked the main terminal wires (+ and -) and ground Chasis wires and seems to be fine. Removed the battery from the bike then check the voltage and it reads 12.9V.

[DiRTeNtwisted]

Never had it happen, but I would recommend tracing all wires and lookin for a damaged wire. From rubbing up against something to make you have this short. That's where I would start. Hope that helps a little!

[07Bolt]

U've got electricity from ur ground cable flowing to ur main fuse somehow. Could mean ur voltage regulator is blown/grounded and its popping ur main fuse. Check ur voltage regulator plugs for ohms or voltage.

[rpatt1]

Check your ignition switch and the wires running to it. I assume you have a lightning not a bolt since you posted in this category - so also check the bundle of wires coming from behind the left hand scoop over front cylinder and up into the flyscreen hollow. If someone isn't careful when they pull left side scoop to change spark plugs - the bundle of wires likes to ride down in and get pinched into fins at the top of the cylinder. Then as you ride it - the vibrations will cause the fin to cut into that wire bundle, eventually leading to a short.

[KC_Buell]

07Bolt - With battery fuse out, will I be able to get any voltage reading off the voltage regulator plug? What is the ohm value I should be expecting?

rpatt1 - Thank you for giving me a good place to start my troubleshooting.

[KC_Buell]

Took the battery out, took apart headlight assembly, unplugged wiring assemblies to the gauges, ignition switch, horn, and headlight but did not find any cut wires that was causing shorts. Here are the orders I put the unit back together.

- Installed the battery back on the bike
- installed the 30A fuse and did not spark
- Plugged the ignition and everything powered up
- Plugged each wiring harness then powered up and did not blew the fuse

It was frustrating to not find the root cause but rode my bike for about 150 mi. now and haven't had any issues yet. Keeping my fingers crossed

[KC_Buell]

Just as suspected, same thing happened again today. Any clue on something shorting like this?

[thrstrmech]

does your bike have the clamp installed holding the battery cables together? if so check the length of the screw, if it's past the nut at 1/8" or more, peel back the covering on the main harness below the battery cables...I say this cause had a very similar issue with mine several years ago where the screw use on the clamp almost severed a wire in the harness causing power loss and blown fuse

[kabuell]

77 connector. Might be worth a look. I had similar symptoms. swapped out the 77 connector and she was al better all the best.

[KC_Buell]

Finally found the source - on the side of the highway :) After peeling back the shielding cloth, noticed the wire (positive wire to the voltage regulator) was in direct contact with the low fairing mount bracket. I made sure the cloth was between the wire and the bracket and inserted the new fuse without a problem and fired right up. Thank you all for your help and hopefully this would help troubleshoot some of you out there with similar issue.

[KC_Buell]

http://i721.photobucket.com/albums/ww217/sehankim/28ac1f92331f791b05f30f4ca79a3132_zps59748f0d.jpg

[thrstrmech]

insulate those wires better, looks like more than one wire rubbing on the bracket

[arqueware]

Had identical symptoms: repeatedly blew 30A fuse with ignition off.
Cause: leads from 77 connector (voltage regulator) shorted to oil line.