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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Electrical - Battery, Charg Sys, Lights, Switches, Sensors & Guages » Archive through October 17, 2009 » Help! Assorted electrical problems, bike runs fine « Previous Next »

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Drum3rjay
Posted on Sunday, June 14, 2009 - 10:19 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Heeeelp!!! I am stumped by my current bike issue; I have a 2004 XB12R and I was replacing a couple of things on my bike. The previous owner did a real hack job on the wiring harness, but I thought that I would replace all the hacked up parts. I redid the headlight and tail harness. I removed 1 of my 2 HID headlights and reinstalled my undertail with all new components. I was testing everything that I connected or disconnected with a multimeter to make sure that I didn't screw anything up and all was fine. So I connected my undertail and did a final mock-up before securing all fasteners; I added 2 small 12V safety lights (connected via brakelight switch to a flasher relay) and pulled in the front brake to test it. The flasher relay made a buzz which is to be expected with a small load on a flasher relay, and then the buzz from the relay stopped after maybe 10 seconds. (Dammit!)

I left things as they were and checked the voltage to the brakelight switch. It read 12.3v to the main taillight (That's good), 1.3-2.1v to the switched light. (Oh no!) My brake light was not flashing, and my relay no longer fired. I checked to make sure that the spades were touching the bulb and the harness was jacked in fine; they all checked out! Strange that my undertail worked ALL THIS TIME and then stopped 10 seconds into the final mock-up without me touching or doing anything!

In the interest of diligent troubleshooting, I switched off the power and turned the key again-this time the dash lights and tail light were completely out. The engine started fine though...very strange indeed! Being that I was simply reassembling a previously working system, I can not see where I might have screwed this up, so it is very difficult to backtrack what I might have disconnected or bumped into, but I tried my best. I got 0 voltage to the tail section that I can remember and I don't even know where to begin with this damn shrink wrapped harness!

My headlights work fine! I had the front section disassembled to try a new wiring configuration for my HIDs, but I reverted back to the original because it made more sense. There is no issue with the headlights, and even though I get no dash lights, when I flick on my Hi Beams, my Hi Beam indicator on my dash DOES light up! That tells me that the dash is not dead, nor is its harness. (that I can tell...)

I am pretty desperate here! I do have a service manual and parts manual, and I am trying to make heads/tails in order to bolster my troubleshooting efforts, but I REALLY don't want to change this whole wiring harness because of piss-poor troubleshooting on my end. Sounds like I'm panicking-can anybody help me out here?! I appreciate it guys!
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