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Old 12-08-2012, 06:27 AM   #1 (permalink)
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Help Possible Smoked Ignition

I replaced the switch on my 2003 ironhorse because I lost the keys to the original one. The ignition was an original replacement with two wires. It had to unplug what I think is the ignition module to get the housing off where the switch was held. I replaced the switch, plugged the module in and hooked up the battery. I tried to crank the bike over before mounting the aluminum housing containing the electronics back to the frame. The electronics started smoking like something fried when I did this. I am certain that I installed the wires correctly so I am stumped why this happened. The only thing I can figure is the housing needed to be grounded but that seems far fetched.
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Old 12-08-2012, 06:47 AM   #2 (permalink)
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now check for frayed wires, & carry a spare key in your wallet. sounds like you have a direct short in the wireing.
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Old 12-08-2012, 08:18 AM   #3 (permalink)
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Quote:
Originally Posted by kcc0521 View Post
I replaced the switch on my 2003 ironhorse because I lost the keys to the original one. The ignition was an original replacement with two wires. It had to unplug what I think is the ignition module to get the housing off where the switch was held. I replaced the switch, plugged the module in and hooked up the battery. I tried to crank the bike over before mounting the aluminum housing containing the electronics back to the frame. The electronics started smoking like something fried when I did this. I am certain that I installed the wires correctly so I am stumped why this happened. The only thing I can figure is the housing needed to be grounded but that seems far fetched.
On some Harley's a ground is possible.. It only started smoking on the start mode? My guess a Ground..
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Old 12-08-2012, 08:33 AM   #4 (permalink)
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You are correct that it only started smoking when I tried to start the bike. The bike was fine before I changed the switch. I can't really see how I have a direct short now. Is it possible it smoked because the housing was not bolted to the frame? Thanks for all the good advice and please keep it coming.
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Old 12-08-2012, 09:21 AM   #5 (permalink)
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I have attached a link below to pictures of the module and switch housing. I think the module is the power control module. The orange and white wires read like they are shorted together which may mean the module is bad. Does anyone know how to test the module and a source to obtain a new one?

https://picasaweb.google.com/kenneth...COjgmd3T_oiHBQ
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Old 12-08-2012, 09:28 AM   #6 (permalink)
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The pics you show are of the switch and a relay...........not really any electronics there to speak of. Wondering if you grounded it out (pulling too much amperage) while placing the metal cover on it.............LOOK for a pinched wire hitting chassis ground.

Last edited by DR_DEUCE; 12-08-2012 at 09:54 AM.
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Old 12-08-2012, 10:21 AM   #7 (permalink)
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I assumed there are electronics in the part that the relay plugs into. It smells burned. The relay plugs into it and the harness plugs into the module. Does this conrol the blinking of the signal lights or something? I am not sure what the purpose of it is.
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Old 12-08-2012, 04:38 PM   #8 (permalink)
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Thanks for the help from everyone. I solved the issue. I left the ground wire going to the starter off when I hooked the battery back up. It seems like a bit of a bad design to have two large ground wires that attach to the single battery post.
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Old 12-12-2012, 06:16 AM   #9 (permalink)
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Quote:
Originally Posted by kcc0521 View Post
It seems like a bit of a bad design to have two large ground wires that attach to the single battery post.
That is a perfectly reasonable circuit design actually. The circuits that use those ground wires are isolated from each other.
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Old 12-12-2012, 07:00 AM   #10 (permalink)
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If all you lost is a relay I would say you were lucky. When a starter is called upon & it has no ground you can bet it will find it somewhere & if it doesnt it will fry itself. The amperage draw without a ground was through the roof. 2 Ground circuits how lucky you were.
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