New wiring harness... - Honda Shadow Forums : Shadow Motorcycle Forum
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post #1 of 17 (permalink) Old 04-19-2017, 06:35 PM Thread Starter
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New wiring harness...

Hi everyone, I've posted before about my 2003 Honda Shadow VT750DC blowing headlight fuses. I have tried all of your suggestions but I can't find the short. I even put it in the shop and they could not track down the short either, so I found a used wiring harness for 03 VT750DC (same as my bike) on Ebay for $29 and I'm thinking I should buy this and take my bike back to the shop and have them install the wiring harness. What are your thoughts on this?

Thanks


Current bikes: 03 Honda Shadow Spirit 750
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post #2 of 17 (permalink) Old 04-19-2017, 07:03 PM
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That could be very expensive.

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post #3 of 17 (permalink) Old 04-19-2017, 07:54 PM
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I wouldn't think it would be that much. Couple of hundred or so? I dont really know. Ask your shop first.


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post #4 of 17 (permalink) Old 04-19-2017, 08:19 PM
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If the headlight circuit/fuses is the only problem and it were my bike I would try running new wires for the headlight thru a relay and see if that would solve the problem. I would definitely try that before going to the trouble of replacing or having someone replace the entire wiring harness. I might also be tempted to run a temporary circuit for the headlight just to see what happened. JMHO.
One other thought how do you know for sure the problem is in the wiring? Just curious.
Good luck whatever you decide to do.

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post #5 of 17 (permalink) Old 04-19-2017, 08:46 PM
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If it is only the headlight fuse blowing I would try to isolate the cause and maybe just run a new wire past the trouble area as mentioned above. It looks like only about 10 feet of wire and 2 switches and the headlight that is involved. Is the headlight a high wattage after market bulb?
Take out the headlight (1) does it blow the fuse?
Disconnect the left handlebar switch (2) does it blow the fuse?
Disconnect the right bar switch (3). If it still blows it is in the span between the handlebar switch connection and the fuse box. It may be easier than you thought.
If you change the harness and it is a problem inside a switch housing the problem will still be there.
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post #6 of 17 (permalink) Old 04-20-2017, 08:05 AM
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As mentioned a relay may help, I've used these before and they work well.
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One end plugs into your headlight connector and the other onto the headlight then you run the fused power wires back to the battery.

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post #7 of 17 (permalink) Old 04-23-2017, 11:59 AM Thread Starter
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Thanks everyone. Swifty, I removed the headlight and went for a 15 minute ride and sure enough when I got back, the headlight fuse was blown. So what does that mean in relation to your 3 step process?
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post #8 of 17 (permalink) Old 04-23-2017, 12:21 PM
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If the fuse didn't blow right away it shows it is an intermittent short, maybe from vibration or turning the bars or the switch wires or contacts short out when moving. If you can rig up a small light bulb in a socket with long wires and slip the ends of the wires into the fuse contacts ( remove the fuse), it will indicate when it is shorting. With the key on pull and twist the harness to the headlight and any other wires you can get to move. Turn the bars back and forth. Switch all the switches. Push the fuse box and wires around. When there is a short the bulb will be bright. If no short it should be off. Put the bulb up on the handlebars. That way you can watch the bulb as you ride and stop and disconnect things in the circuit.
But look carefully at the wires where they go out of the headlight bucket first. Look for a cut or black spot on the wiring.

Only a biker knows why a dog sticks his head out of a car window.
1983 750 Shadow
From the past=
1951 Cushman scooter
1962 Honda 305 Dream
1965 Honda 305 Dream
1971 Honda 175 scrambler
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post #9 of 17 (permalink) Old 04-23-2017, 04:35 PM Thread Starter
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Swifty, I pm'd you, but I forgot to ask if a fuse tap without a fuse would work if the other end of the fuse tap supplied power to the light (I was thinking of using a blinker light off of a Tomos moped as the light)

Current bikes: 03 Honda Shadow Spirit 750
2013 Kawasaki Ninja ZX-14R (slightly modded 208 RWHP)
1999 Tomos Sprint A35 moped
**********************************************
Previous bikes: Honda CT70
Honda SL100
Suzuki TS125
Suzuki 500 Titan
Yamaha RD 350 (slightly modded)
Honda CB750
Kawasaki KLX 110L
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post #10 of 17 (permalink) Old 04-23-2017, 05:39 PM
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Any normal auto type bulb will work as a circuit when put into the fuse connections. With the fuse out the bulb will complete the circuit and light up when there is a short on the output side of the fuse. The input side of the fuse is powered when the key is on. No powered needed for the bulb except the fuse circuit.


Only a biker knows why a dog sticks his head out of a car window.
1983 750 Shadow
From the past=
1951 Cushman scooter
1962 Honda 305 Dream
1965 Honda 305 Dream
1971 Honda 175 scrambler
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