Bonneville America Forums Forums Technical Forums General Tech Popping Fuses

Yet another electrical problem on this bike, I've popped two fuses each on the #8 and #10 fuses, both 5A fuses. The #8 fuse is for the speedo / tach illumination, and the #10 fuse is for the front position light / rear tail-light. I've pulled the rear fender to inspect the wiring to the rear tail-light, and it looks fine. As near as I can tell from the lighting circuit diagram on page 16.66 and 16.67 of the service manual, the only device that the two circuits have in common is the ignition switch. If anyone can lend assistance, I'd greatly appreciate it! Thanks. At least my fricking car is reliable!

I remember having a problem with the tailight failing to illuminate earlier in 06 and I took it to the dealer for repair.

The said a short existed somewhere in the headlight nacelle.

They ended up bypassing the position light as they nerrowed it to that. The position light is not someting we need in the states so it was no bother to me to bypass it. I wanted to get on the road and did not want to wait for them to isolate fix the problem so I told em to just bypass it and be done with it.

Try removing the bulbs in the Speedo... and replace the fuse.

Twice I have had the fuse blow due to the bottom bulb blowing out. On mine, (02) the tail light is on that same circuit with the speedo lights.

Kevin, I'd figured that there was a short somewhere, how did your mechs bypass the position light? Did they just disconnect the wires from the fixture? Beavis, I actually do have bulbs coming in for both the speedo and the tach. I had replaced the fuse for the speedo/tach, about 3 weeks ago, the speedo light worked, the tach didn't. I haven't checked the bulbs themselves in the speedo. Thanks for the inputs guys!

Hi
i had the same problem some time back, it was were the wires enter the headlight, there is a rubber ring that fits around the hole were the wires enter, this had come away and had worn the plastic sleave on one of the wires, that in turn kept blowing the fuses.
all i did was tape up the worn wires and refitted the rubber seal with a little silicone sealant to hold in place. no more problems now after about 12 months.
hope this may help
Safe riding
Herb

I also agree to check the headlight area first. There can be a lot of rubbing going on in that area and the wiring you need all passes thataway.

Herb and Dink, thanks for the inputs, I'll check those tomorrow morning. At least the bike had the good grace to throw a hissy when I'm still on vacation!

Watch those wires going into the back of the headlight as you turn the bars lock to lock.... You'll see they go in,out,in,out,in,out,in,out..... I covered mine with loom and made sure the rubber ring was in place.

Now I need a cigarette.

I had this same problem back in the spring. The cure was the wire going to the taillight was pulled to tight and it was crimped where it went through the finder. I pulled it back and made sure there was some slack. After that everything started working and fuses quit blowing. Now every couple of weeks I check the slack. When I was having this problem I called the dealer in Batesburg SC and he told me they had seen this several times mainly late 03’s and early 04’s.

Thanks guys.

Ended up taking several bits of advice, and everything seems to be working. I disconnected the plug connector that leads to the parking light, I separated ALL the connectors in the headlight bucket, removed the bucket, and put several wraps of electrical tape over all of the wire runs that go into the bucket, and I rigged about a half inch of slack into the cables that lead to the tail-light receptacle. The Tailight is on and stays on, the fuses aren't going out, and the speedo is illuminated. Thanks again for all the advice doods!