Electrical Issues

Sorry to hear about this. Any answers yet? Like one other Roadster owner here, my starting relay fried early on and necessitated harness replacement.
Gotta wonder if your issues don't go all the way back to the stator.
 
This could very well be another effect of not having headlight relays fitted. First the ignition switch (updated) next the ignition plug (updated) now the starter relay, loom, and regulator. From what I have heard the headlights play a roll of using excess power generated from the alternator and if not used by the lights will over charge the battery. If you have seen what that current has done to the switch you can understand what it can do to the loom and other components. Fitting relays may cause your bulbs to blow more frequently but believe me that is a lot better than having the loom melt down or the regulator frying.
 
Okay, I got the bike back yesterday, according to the dealer, there was a short in the wiring harness. That has been fixed, and the bike tested good, so I'll give it another try. Rode it for about 100 kms, and all seems well. I'm not sure what the deal is with the headlight relay you mention. Is there a replacement relay, where is it located, because I don't need any more issues with this bike, riding season is almost done here, and I won't get to use it much until next year. any upgrades I can do to prevent electrical issues next year would definately be helpful.
 
thanks, went through the thread, but it's all greek to me. Are the relays mentioned in the diagram, aftermarket? that are fitting to an existing socket, or are they being spliced in? If so, what are the relays (brand, part #, etc) Sorry, but i'm not an engineer, just a guy trying to make it so he can ride his bike. B
 
..a lot of us here got the plug and play relay kits from http://www.easternbeaver.com/ you'll want the H4 dual headlight relay kit (the one for $54.95)..I bought the dual horn relay kit too (two stebels on my beast), and the 3 CS Link Removed ..that made everything plug and play and only one other set of leads to put on the battery...think about it and do it over the winter if ya decide to..the wiring kits are high quality stuff..
 
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