| Author | Message | |||
     Jakecheez |
I had a thread on here called perfect ride...... ruined This is in continuation: Quick recap: 2003 XB9R -the ignition fuse blew thirty miles after I got the headlight recall done. -it blew while moving, right after I let up on the throttle. -it's never blown when I'm going >40mph -it has blown while the bike is completely stopped -10 fuses blew before stripping it of all plastics *I searched high and low, front to back for a posse wire, worn insulation, ect. I found nothing *I brought the bike to defiance studios (custom choppers) and Noelski searched everything for a wire, he found nothing. *I brought it to the dealership. They checked all wires under the front fairing in case they bumped somthing while doing the recall. They found nothing. Now, do I pay $100 an hour to have them find the problem? HD informed me that it could take 10 min or 10 days. I could be out $10,000 and still not have a solution!!!! Any ideas? Thanks guys- | |||
| Pogue_mahone |
what is the cost of a new harness?and can u install one ?i read some harness wierdness before,maybe u have older one,maybe new one will have bugs fixed? | |||
| Jakecheez |
What, a fuse harness? Not sure, but I'll look into it. BTW- I told the dealer to put a $300 labor cap on it. If they can't find it by then, I don't know what to do. | |||
| Iamarchangel |
Way back at the beginning, we talked about relays. Did you replace them or switch them around? If the HD people don't have multimeters, wiggle boxes, etc., not much point leaving it there. An intermittent problem is just that. You can only find it just before it pops. (Electricity runs on smoke, once the smoke gets out, no electricity.) The cap was wise. You might get lucky and they find it in minutes. You're not expressing much confidence in them.
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| Rsh |
I think I responded to your original thread. I had a problem sort of like your's. In my case it was the speed sensor causing the ignition fuse to continually blow. When I disconnected the speed sensor (the connector is under the front pulley cover) everything was good. It's worth a try. | |||
| Jakecheez |
Sounds good. Both suggestions: I have not checked the speed sensor or the relays. I'll do both. The lack of confidence I expressed regarding HD was a result of confidence the service guy expressed to me, regarding the situation. | |||
| Iamarchangel |
You'll see from the wiring diagram attached in the previous post that there's only a few wires connected to that fuse circuit. Changing out the relays would have been among the first steps in the troubleshooting process. | |||
| Jakecheez |
Thanks for the heads up. The relay is the first thing I'll work with now. But, I can start the bike, shake it around and the fuse "usually" won't pop. I have to ride it around for a few miles. Even then, it might not pop. Is there a way to run the bike without having to "buy" a new relay? | |||
| Midknyte |
Changing out the relays would have been among the first steps in the troubleshooting process. After fuses, they're also the next cheapest thing you can do. They only run about $7 or so. You'll notice (at least on the Firebolt) an open extra socket under the cap where you can stick a spare in.  | |||
| Iamarchangel |
After fuses, they're also the next cheapest thing you can do. They only run about $7 or so. You'll notice (at least on the Firebolt) an open extra socket under the cap where you can stick a spare in. I did not notice, thank you for that info. Do you know the auto model name/number for a relay or is it a Buell part? | |||
| Fast1075 |
Twice when I tried to open that wiring diagram...nasty things happened with my computer...total freeze-up. | |||
| Midknyte |
Not off hand, but my dealership had them on hand. Should be a stocked item that you can walk in and out of the shop with. I think you can pick up an equivalent relay at an AutoZone or such too. | |||
| Jakecheez |
Primo! That makes the relay troubleshooting easy. I'm grabbing the bike tomorrow and I'll see if that is the problem. | |||
| Iamarchangel |
'03 parts book number is 31522-00B. Chicagoharley doesn't list that number, lists a 31522-00C which is a relay. It's $4. Same part? | |||
| Jakecheez |
I think so. I called St Paul HD and they told me that the relays are interchangeable (between started, ignition, ect.). The part is $5 at this dealership. If I replace it and that was the problem, I will sigh in relief then kick myself for not doin this first. I'll post an update on Sunday when I know if it worked or not. | |||
| Ochoa0042 |
have em redo your recall... sounds like that will be the solution | |||
| Thatman |
+1 on the recall, if all this started happening after the headlight recall was installed then that is your problem... | |||
| Chainsaw |
I had a problem sort of like your's. In my case it was the speed sensor causing the ignition fuse to continually blow... I second that opinion. Same thing happened to my 03XB9R many moons ago. Unplugged the sensor, bike ran fine. | |||
| Iamarchangel |
Stick to basics, check the relays first. If you really think that they messed up the recall, why bother going back? They've already told you what their top guesstimate is going to be. And, you'll never know if it's related until you find it. So, happy hunting. The other posts are not necessarily wrong. You're just not there yet. You're able to open the attachment, aren't you? I don't know how to post it as page which is what I'd rather do. | |||
| Rsh |
It seems like it would be really hard to mess up the headlight recall in terms of wiring, unless a wire was somehow pinched, or the hot wire and ground were reversed to the bulb connections, stranger things have happened. Maybe it is something else, I read another post by Jakecheez and he does have a power commander in the system, it could be a little more complicated. | |||
| Iamarchangel |
Yes, I just had a look at his profile. There's a lot of work on that bike. Also checked the Power Commander website and they don't have a model for any current Buell. Anyway, electricity is just logic and smoke. He just has to check everything that hits the ignition fuse circuit. First check the wires at the fuse connection and underneath the relays. Second check the relays. Third check the key switch connector Fourth, track the Gy/O and R/Bk wire from end to end. It could take 10 minutes or 10 hours. | |||
| Jakecheez |
St Paul HD has already had it for 8 days and they are iffy about getting into it. They checked the recall and everything looks fine. They tell me that now it gets into the ten day treasure hunt thing. I gave them the thumbs up to start working on it last Tuesday and they need to get permission from the shop foreman who has to be there at the same time as both the service advisor and the tech, which won't be untill next Monday to decide if they will even start working on the bike. So I am going in tomorrow to put in new relays and take it out for a spin. If it still pops, I may end up dropping it back off there. -Is the speed sensor somthing I can check myself? If so, where and how? -Is the key switch connector somthing I can check myself? If so, how? -I checked the gy/O rd/bk wires and everything that's not heat/shrink wrapped looks good. -the wires underneath the relay and fuse boxes all look good (not bare or burnt) The shop did tell me that since it is the key switch ignition fuse, it could be any wire on the bike. Not just a wire on the ignition circuit. Any truth to this? It just didn't seem right to me. Also, I do have a power commander on the bike and I know that it needs to come off, but untill I figure this out, I don't know if I will take it off. Plus- with the other mods on the bike, im sure i need a tuner on it. The Daytona tec tuner is the one ill replace it with. Without an endless supply of money to fix this problem, the tuner is not my first priority. Unless the power commander could be the problem, then I need to take it out now and put in the tec tuner......... Thanks so far guys. | |||
| Iamarchangel |
I would leave the speed sensor for now. It is working so that's lower on the priority list. There's a smaller snakepit of wires behind the sprocket cover. There's also a 77 connector there that may be a suspect but I doubt it. The key switch connector is below the key switch and part of the bigger snakepit under the fairing. The Rd/Bk wire there is connected to the ignition fuse. Look for any flaw/wear. The purpose of having fuses is to isolate circuits so I'm not sure what they mean. Again, there could be interference from another circuit, that's part of what fuses protect from but first look for problems within that circuit. Any fuse could be affected by any other circuit. Have you ever had any other fuse pop? Do you have a day or a week before the shop foreman is there? | |||
| Niceguyeddy |
ask to speak with Lance Kuegler, he's the go to Buell guy@ sphdb. | |||
| Andymnelson |
Lance is great, but he's the parts manager. He has no connection to the service guys. The few times I've asked service related questions of him he's had to go ask the "service guys". | |||
| Jakecheez |
It's been there a week , now I have just one more day untill the shop foreman is there. I called yesterday to let him know I was gonna be in today to check out a few things. It's all torn apart and I just don't have the time today to put it back togather, test ride it, then take it back apart. I'm leaving it there another week. If anybody thinks fairabult HD is better, please let me know. | |||
| Niceguyeddy |
I prefer Fairibault. Never any problems with them over the last 11 years. Solid Buell tech there, ask to speak with George Bennett. | |||
| Tq_freak |
he relay is the same as a 200 ford focus A/c relay, about $5 at auto zone (they are usually goons and need to look up by application and not part number) Check where the harness goes around the neck bearing under the plastic retainer. VERY common to wear there on the 03's Very common. | |||
| Iamarchangel |
Checked with my local dealer, Rocky's, they had two in stock for $7 apiece. Now, they have one. This will go in the spare slot. Seems to be wisdom to have a spare. | |||
| Thatman |
Jakecheez Sorry I’ve been a little buzzy, that file is a tiff or a scanned image. Just change the file extension from .unk to .tiff and Microsoft picture manager will open it. |
Ignition Wiring Circuit