Total shut down of electrical system

Discussion in 'Electrical' started by Big John 57, Sep 15, 2011.

  1. Big John 57

    Big John 57 Member

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    My 02 Ultra Classic is driving me crazy, bike started out this summer shutting down total loss of electrical power ( clock did not loss power ) I would on side of the road turn the key switch off and on couple of times and power would be restored the bike would run ruff for a few mins. then all was good.So what I have done to correct problem, I replaced the systems relay, replaced 40 amp main resetable breaker, also up this breaker to 50 amp, changed out the key switch assemble, what seams to happen now is when I turn on the running lights along with the headlight the 50 amp breaker will trip after riding for about 5 mins. it will reset with in 1 min and I restart the bike again running ruff. What could be pulling so much current. I use to ride with my driving lights and headlight on all the time with a 40 amp breaker with no problems.I have not added no new electrical items to the bike or had any work done to the bike this just started happening one day
     
  2. HDDon

    HDDon Experienced Member Contributor Retired Moderators

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    Someone will come on and ask you some tech ??, but it sounds like you have a wire or wires that have rubbed the insulation off and is causing a dead short.
     
  3. glider

    glider Veteran Member

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    I think I would check out the battery cables myself for openers. The connections on BOTH ends of all cables. Clean both ends reinstall them and do a test on them.

    Harley Davidson Community
     
  4. R_W_B

    R_W_B Senior Member

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    This one ought to be interesting. Hope it's the connectors like Glider said, but you got some kind of slow or intermittent load on it. A short I would think would blow another fuse before the main fuse blew. Usually for a main to blow without any circuit fuses blowing, it's a system overload but no individual circuit has been overloaded.
     
  5. Big John 57

    Big John 57 Member

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    I have cleaned and checked all cable ends the battery is about 15 months old
     
  6. wilks3

    wilks3 Junior Member

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    Could a grounded stator assembly or VR be the cause? 50amps is a bunch of draw. Especially because it does after 5min or so. Wouldn't a dead short pop breaker immediately?
    wilks3
    :USA
     
    Last edited: Sep 16, 2011
  7. R_W_B

    R_W_B Senior Member

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    Yes you are correct a dead short would be immediate or very close to immediate. Something is causing a lot of current to flow distributed over the whole system evenly OR there is a part of the system that is not indiviually fused and is only protected thru the Main fuse.

    Your stator failure is an interesting item. I've never heard of a stator failure blowing the main fuse, HOWEVER all the other symptoms DO agree with stator failure.

    One thing for sure if he doesn't find the culprit soon, it could cause the stator to fail even if it's not the problem initially.
     
  8. Breeze3at

    Breeze3at Well-Known Member

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    If it only happens with the running lights ON, the problem is somewhere in that circuit. Check from the point the wires exit the bulb socket on back. Even a tiny chafe will do it. Tedious process but necessary.
     
  9. R_W_B

    R_W_B Senior Member

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    How big a running lights are you running ? My stepson had some lights he referred to as 'spot lights' that he was running at night all the time. He did not have a blown main so not quite the same thing. But it did drag his battery down to the point where his lights started going dim.

    He replaced the battery and it was ok for awhile until his stator went bad and he had to replace it.
     
  10. wilks3

    wilks3 Junior Member

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    Lights drawing over 50amps? Wow. You can weld with 50amps. Something drawing that much should get hotter than all get out!
    Can you smell the primary oil? Maybe drain alittle out. Check color and smell.
    This will be an interesting find and cure problem!!!
    wilks3
    :USA