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Electrical help needed
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  #16 (permalink)  
Old 09-12-2017, 05:37 PM
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Try to ohm all those wires around the high beam switch to ground to see if maybe something melted to ground....then do the same from wire to wire...it seems that it would have to be a fairly large wire not to go up in smoke, but just trip a breaker...

Question...you say when you started the bike , the positive battery cable...the one that hooks to the battery, got hot....how about if you don't crank the bike? does it still get hot just by turning the switch on?

Your charging wire from the regulator goes to the battery, this is not the one getting hot is it? this one is pulling 20 amps by itself .......it's the other larger cable thats getting hot? the one that goes to the starter..?


Here is one other trouble shooting tip.....Your ignition switch test has proven that you have a bad or dirty switch....I would keep my jumpers in place while troubleshooting other areas.to guarantee success.
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Last edited by Shovel52; 09-12-2017 at 06:32 PM..
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  #17 (permalink)  
Old 09-21-2017, 12:37 PM
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OK, so today I got the bike running, and it ran for a couple of minutes then died and no lights, I removed all the self re-setting circuit breakers (they are on the belt drive) and put in hard-wires, put the key in the ignition and turned it on like normal, the lights would only come on and t would only start if the jumper wire from the battery was connected to the middle wire of the ignition switch (the power in supply) as soon as I unhooked the jumper cable, everything dies, All while doing this I had the headlight unhooked. if I re-connected the jumper cable everything comes back on, spark, ignition, lights. etc. SO this rules to the circuit breakers. is there anything down by the started that could be tripping the wire going into the ignition? Edited to add.....there is definitely a draw somewhere because I haven't touched the bike since last week and it didn't have enough juice to crank, after a short charge is was back to 100%
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  #18 (permalink)  
Old 09-21-2017, 06:21 PM
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The hot wire to the ignition switch usually comes straight off of the starter, they do that to clean up wires coming off of the battery..they then go to the breaker and then to the ignition switch...
if you are sure that wire is bad and it's not the ignition switch itself, i would disconnect the starter cable at the starter and see if relieves the draw down..sounds like something is wrong right there..you said before that the big wire to the battery was getting hot..sounds like the starter..keep in mind that the voltage regulator hooks directly to the battery too, you could have
shorted diodes in the regulator also..disconnect that that wire from the battery and see if it relieves the short..a milliamp meter is useful for that....it sounds like the draw is pulling your battery down too low and killing the bike...
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1975 Harley Davidson Shovel head Chopper
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Last edited by Shovel52; 09-21-2017 at 06:34 PM..
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