I apologize up front for this long post.&nbsp\\;\\\\\\; For some reason I cannot get all the information into one posting so I will break it down into several smaller postings.&nbsp\\;\\\\\\;
Riding home sunday on a weekend trip my bike dies as I am riding highway speeds.&nbsp\\;\\\\\\; I get the bike on a side road and begin intial troublehsooting.&nbsp\\;\\\\\\; I have no front end lights, bike will not crank.&nbsp\\;\\\\\\; More to follow on the next post.

 

Found the Security fuse was blown.&nbsp\\; This fues would pop with the ignition on or off.&nbsp\\; Eventually I did get the bike to crank up and run for a few minutes. Afterwards I had no spark and the biek would die again.&nbsp\\; Still no front end lights.&nbsp\\; More to follow on the next post.

 

I got the bike home via a borrowed trailer.&nbsp\\; I spent several hours troubleshooting. Here is what I know so far:
[ol][*]The Turn Signal Module (TSM) was fried. It had a real bad smell of burnt wires. Got a new one from HD and replaced it. That got the bike so it would crank but not start.[*]Still no front end lights.[*]I decided to disconnect the PCIII. Afterwards, the bike would crank and run, but only if I had the throttle above idle. If I went back to idle the bike would shut off. So now I figure a fried PCIII as well.[/ol]more to follow on the next post

 

I called the tech at the local HD shop about the running issue. He said the bikes memory thinks the PCIII is still installed and needs to be reset. This is done by disconnecting the battery for 15 minutes.&nbsp\\; I tried that...same results. IIRC when I installed the PCIII last year I did not have to reset the bikes memory.
Now the front end lights, or lack there of.
My headlight, passing lights, front turn signals and one rear turn signal bulbs were all blown. I had tour pak lights, tail/brake lights and fender lights. No problem on that, I can get new bulbs. Also the odometer will not work. All other gauges function normally. There are no burnt/shorted wires. The main wire harness and the interconnect (Fairing) harness are new (replaced last year) during the police to ultra conversion.

 

Now the questions:
Will a faulty/blown TSM cause the lights to blow?
Will a faulty/blown TSM cause the PCIII to die?
Will a faulty/bad PCIII cause the TSM to die?
Has anyone heard of resetting the bikes memory after a PCIII install or disconnect.[/align] So today I will get a new PCIII and new light/bulbs and try that. Replacing the TSM got the bike back breathing, so I am closer than before.
For the record, I do my own wrenching on all vehicles. I have virtually had this bike down to the frame during the police to ultra conversion so I can honestly say I know it inside-out. Your suggestions are welcome and wanted.&nbsp\\; Fire away. I have my service manual and parts book on hand.[/align]

 

Again I sincerly apologize for the method that I had to post all this information.&nbsp\\; Your comments and suggestions are welcome.

 

Were you anywhere close to AREA 51?

 

With everything blown or fried I would start checking the charging system. Sounds like you are putting out max amperage for to long. Now that you have it running check charging voltage at battery if it is 15-16 volts that is the place to start. Hope that helps?

 

Yep. I thought about that also. I will check tonight when I get home.&nbsp\\; I am also replacing all the relays, since they are not too much $$$. I will keep you all posted on the progress. Keep the suggestions coming.

 

Blown lights = too much voltage.&nbsp\\; Check regulator or possible short or open to regulator. Try initial test using service manual&nbsp\\;and voltmeter,&nbsp\\;since electronic modules really hate high voltage. On battery power only try wiggling harness' to see if any relays or fuses trip. Good luck.