That's a great find. If I a finally reading the correct diagram, on the 07 the wiring is strange. It appears to have two power circuits, regulated and unregulated. The power from the regulator (Red Wire) only powers: 1. battery charging (the 15A fuse) 2. condensor 3. horn 4. turn signals & flasher 5. speedo A short near any of these will blow the fuse. The remainder of the power for the whole bike comes straight from the generator on the (Yellow wire) and is not fused anywhere. Not a very good design. Hope this helps. Cam.
Problem Found! Dam thing was in the ignition switch. Dealer and myself were ready to give up. Luckily out of nowhere it started blowing the fuse immediatly after turning the bike on (never did that before it would always run awhile) New ignition switch on the way. Perfect timing now that is 10 degress with snow and ice on the ground. Thanks for all your help guys. P.S. that f-ing bike is going to pay for this next spring with some serious beatdowns
How high was the voltage w/ the old vr? Maybe it smoked something in the ecu? IIRC the bike would run at one point but won't run period anymore? Where do you live? .
What conditions/symptoms led you to beleive it was the ignition switch? Given numerous past issues with husky wires I would lay my bets on the wiring harness. Can you make the fuse blow without the engine running? It may be possible to unplug some stuff for testing. I'll bet you are not having fun. Cam.
Just returned from a trip where mine did exactly the same thing, lost the speedo/gauge cluster, only the green headlight indicator and the green neutral indicator lamps stayed on. At the first overnight I found a 20 amp fuse was blown, I do not know which fuse it is as i did not have the manual with me. I changed the fuse and the cluster returned to normal (mostly the bright light indicator would not switch off although the lights worked correctly). Ten minutes into the ride the following morning everything dead again. I completed the ride and returned the bike home and have not even unpacked it yet. My bike is a 07 EFI bike, which I think is the 08 bike States side. Help would be appreciated before I start stripping (oh i did fit LED flickers which I could not get to flash correctly and a few months ago I lost the turn signal indicator on the cluster.)
thinking out loud here... Will the bike start and run without the gauge cluster plugged in? If it will, run it that way for a while and see if it blows the fuse. Maybe a short in the gauge... I just went thru a similar fuse blowing episode. Ended up being wires plugged into injector had rubbed on the injector rail and were shorting intermittently as I hit bumps. You may have something similar, but God knows where. On my 630 I think the main harness is pressed awfully tight to the frame by the rear of the fuel tank, I'm watching it for signs of chaffing. Did you install a part with your blinkers to get them to flash correctly? .
I tried two different LED relays but neither of them worked at all the blinkers just stayed on all the time. Just before I lost the gauge cluster the blinkers were working but the rate was much faster than in should have been. Without the guage cluster the bike ran 100% without even a hiccup, although I had no lights, brake lights horn etc (luckily I refuse to ride at night).
Yea i tried running it with pretty much everthing i could unplug guage, lts, blinkers, you name it still blows the f@#ker. Its winter here now so ive all but given up for now. Hurts my head to think about. Been riding all kinds of bikes for almost 30 years and have never had a problem this severe. This is my first husky and i loved the bike but dont know if ill ever buy another after this.
My 06 te 610 had been blowing the main fuse periodically for a couple of years. I found this "thread" which motivated me to check all wires for a short. As I was looking with the ignition/lights on, I noticed the brake light was activated-bright. I stepped on the brake and the fuse blew. A quick search of the wires I found two that were sticking together. Didn't really look melted. But I could see a very small exposed area. I separated and taped the wires and no more blowing fuses. Btw, want to show the Buell headlight and custom Mask I made for the bike. View attachment 23222 This light is sweet!!
