Hello guys,
Hopefully someone can help me, as i'm currently at a loss with this issue!

Ive just changed the handle bars on my '97 Sportster 883. As my bike had tucked wires on the previous bars, i thought i would continue with this on my new bars. Rather than dismantle the controls, It seemed the easiest option to cut the wires further along (roughly by the head stock), remove from old bars (along with controls etc), then re-thread the wires through the new bars and re-join the wires properly (solder, then heat wrapped for insulation).

All went to plan and everything was re-connected properly and individually insulated.

Onto testing:
After re-connection i tested both indicators, headlight (main beam etc) & horn. All worked correctly and without fault.
Next i tried to start the bike. The starter motor engaged for a second then died and all electrical power was lost, no lights, no indicators, no horn - all dead!

My feeling is that i have blown a fuse of some sort however i have checked the four spade fuses under the seat and all seem to be fine.

Im not sure what else could be at fault. The re-joined wires all look fine with no shorting or exposed areas.

Does anyone have any ideas?!?!

Thanks for reading!

 

Not an expert on older machines, but is there a master system fuse like on the current models? In line with the battery to fuse block?

 

Thanks for your reply.

to my knowledge there is no master fuse on the bike (although I agree that this issue sounds like that's what would be at fault).

im wondering if I've blown the starter relay, but then would that cause the symptoms of no lights etc?

thanks again

 

Like I said, no expert on older machines.
But in general, get a tester starting at the positive terminal and continue down line till you don't get voltage.

 

https://www.hdforums.com/forum/elect...html#post67046

Third link in this post has a diagram showing a 30amp master circuit breaker.

 

This is for a 1998 Sporty but your 1997 might be the same. It shows the circuit breaker location.

 

Check the main starter relay under the seat. I had a 1991 and there is main power relay. If it doesn't click or is worn out you will get no power to the whole bike. Also, pull the battery cables off and take some sandpaper to them contacts and make sure they are clean. Mine was notorious for having this issue.

 

Thanks for that,
i was wondering if the starter relay would cause general power supply issues. Maybe I will try that first as the 'easy step'!

 

Go here, enter VIN, & look under Vehicle Documents for Wiring Diagrams


https://serviceinfo.harley-davidson....cle/lookupForm


You do have a 30 Amp Circuit Breaker on your 1997 Sporty. All power has to go thru that breaker first, then to the Ignition Switch, then to the fuses (depending on the position of the IGN switch .... ACCY or RUN/ON