Electrical runaround 2007 TE 610

[camms]

So its been almost 2 months since i posted about blowing the main fuse. Took month and a half to get new stator and vr. Put both in and still blows main fuse. Have checked and rechecked every wire on the bike 3 times! Battery is fine and i am not, dont know what to do. When problem first arose fuse would blow and all electrical on bike die but bike would continue to run until you shut it off. Then replace the fuse and it would start up and run again for awhile then happen again. Over and over and over. Now here is the new twist this last time when fuse blew bike died with it, pulled over changed fuse, bike turned on, went to start it bike will crank over but not start. Could this new twist be the the cause of the origonal problem? Could really use some help dont know where to look next. My first husky and i absoutly love the bike but am ready to ghost ride it off a bridge at this point. HELP!

 

[DYNOBOB]

I went back and read your original post...

"Wondering if anyone out there can help?
My te 610 blows the 15 amp main fuse after i ride for couple minutes.
Bike continues to run after screen goes blank then resets.
Ive checked and rechecked every wire on the entire bike. Unplugged everything
that i could and rode it and still bloes the fuse. Checked voltage with bike running and off
voltage is ok. Any ideas."


-15 amp fuse sound awful small as a main fuse, maybe try a 20 or 25 amp?
-Disconnect the battery and hook a voltmeter set on buzz/continuity mode to the positive wire and frame. Does it buzz? If so, start moving the wire harness to see if it stops buzzing. (Don't know if this would work, might get continuity thru bulb filaments?)


.

 

[camms]

Hey cam and dynobob thanks for the responses. Here is what i know.

1. Bike is a 2007 TE610 5400 miles
2. Fuse does not blow at idle only under accelaration not at any specific RPM
3. Stator was replaced at dealer vr by me (was testing at high volts thought that had to be it)
4. Tried 20 and 25 amp fuses. Same result.
5. Cam 630 is different but if i had to guess it would be #8 on your picture
6. Bought it this year with 4500 miles ran f-ing awsome until this
7. Dealer is qlueless
8. Battery is brand new (il try one from one of my other bikes)
9. Ive checked every wire routing, wire harness 3 times cannot find anything

Here is what i dont know
1. Why did the bike die the last time and why will it not start now

Bike is back at dealer they offered to work on it for free because they thought it was the stator, replaced it charged me and that didnt fix it.
Cam i will relay your test to them and see what happens.
The most sickining thing about this is i am an electrican, That has provided alot of material for my riding buddies. Bastards!

Thanks again guys ill keep you posted, let me know if you think of anything else.

 

[Stroker Ace]

Does this bike still have the og. headlight??? They have been known to short out. maybe short in kill switch at handlebar??? maybe short in the headlight commutator on the clutch side??? Maybe the clutch saftey switch??? Lot's of crazy wiring under the rear fender!!! could be a short there for sure....

Does it turn over and not start, or the starter is dead too???

 

[camms]

Hey guys thanks for the info, i will try a different battery see if that works, if not tear everything again and test the shit out of it again.

 

[camms]

Does this bike still have the og. headlight??? They have been known to short out. maybe short in kill switch at handlebar??? maybe short in the headlight commutator on the clutch side??? Maybe the clutch saftey switch??? Lot's of crazy wiring under the rear fender!!! could be a short there for sure....

Does it turn over and not start, or the starter is dead too???

headlight is now trailtech have checked all those thinks and there fine. Also disconnected all those things and it still does it. There is just something hiding very well that i cannot see im gonna try a new battery dont think thats it but never know.
thanks again

 

[JonXX]

I notice that the 2008 TE610 electrical diagram

Just a side observation, his bike is an 07 (carbed) not an 08 (fi) and is wired differently than the diagram you are looking at.

I suspect there is a broken wire(s) in the loom where it squeezes between the frame and radiator. I had a similar (but not same) issue on my 07 SM and the solution was to patch that section of loom. Good thing I'm already bald or I'd have pulled my hair out looking for it.

 

[camms]

The best I can find is the 07 TE-SMR 510 owners manual with an electrical schematic. I hope it is close. You are right in that it is wired a bit different. Its too bad there isn't an electrical manual avail like the 630 one. It has more info and better diags. The 07 owners says 2ea 15A fuses but I can only find one on the schem. Any idea where the 2nd one goes? Cam.

I got a diagram for an 07. Bike is still at dealer, should be hearing from them soon saying "they cant find it" So i might be calling on you guys again once i get it back.
Thanks again for your help cam!

 

[zooker]

This thread is well timed, as my 06 SM610 started doing something very similar last week.

My symptoms of the issue are as follows:

1. Whilst riding the bike I noticed the speedo/gauge cluster going crazy with all of the warning lights randomly flashing. The speedo background then blanked out then started displaying random characters that changed and flashed. The indicators were also going crazy and flashing randomly without me even flicking the switch.
2. This only went on for about 10-15 seconds then all the lights and the speedo went blank
3. The bike was still running
4. I turned the bike off and it would not re-start
5. I found that the same main 15A fuse had blown
6. I replaced the fuse and turned the ignition on and the gauge returned to normal
7. I started the bike and when I gave it a few revs the exact same problem occurred and the fuse blew again.

I haven't had time to inspect it yet but will get onto it in the next few days. I hope to god that you find a solution soon so I know where to start looking

 

[camms]

This thread is well timed, as my 06 SM610 started doing something very similar last week.

My symptoms of the issue are as follows:

1. Whilst riding the bike I noticed the speedo/gauge cluster going crazy with all of the warning lights randomly flashing. The speedo background then blanked out then started displaying random characters that changed and flashed. The indicators were also going crazy and flashing randomly without me even flicking the switch.
2. This only went on for about 10-15 seconds then all the lights and the speedo went blank
3. The bike was still running
4. I turned the bike off and it would not re-start
5. I found that the same main 15A fuse had blown
6. I replaced the fuse and turned the ignition on and the gauge returned to normal
7. I started the bike and when I gave it a few revs the exact same problem occurred and the fuse blew again.

I haven't had time to inspect it yet but will get onto it in the next few days. I hope to god that you find a solution soon so I know where to start looking

What's up zooker. That's exactly how it went down with my 610. Guage cluster
Goes bezerek everything flashes then goes dead but bike still runs. Except now mine does not.
I have went over every wire/harness ect. With a eagle eye and cannot find anything. Cam brought
Up alot of good ideas to look into. I'm thinking its not battery now since you have the same
Problem! Keep in touch we got to figure this Sh-t out!

 

[Stroker Ace]

The best I can find is the 07 TE-SMR 510 owners manual with an electrical schematic. I hope it is close. You are right in that it is wired a bit different. Its too bad there isn't an electrical manual avail like the 630 one. It has more info and better diags. The 07 owners says 2ea 15A fuses but I can only find one on the schem. Any idea where the 2nd one goes? Cam.

The second one is a spare...... man this is strange...

 

[zooker]

PROBLEM SOLVED!!!

Pulled all the plastics off today and spent an hour going over all the wiring looking for shorts. I had the ignition on and wiggled each bit of wiring to see if I could locate the short. Starting at the back of the bike I worked my way forward and reached the front with nothing found . Then I noticed that the bolts for my horn had fallen out and it was just hanging by the wires and one of the terminals was not insulated and could hit the frame. Since I'm not one for dicking around I just pressed the exposed terminal against the frame and got a whopping spark and a pop as the main fuse blew again. I suspected I had found my short

A bit of electrical tape, a new bolt and a few minutes to get the bike back together and away she went. Went for a quick 50km ride and no issues at all .

camms I hope your issue is as simple as mine.

 

[camms]

Problem Found! Dam thing was in the ignition switch. Dealer and myself were ready to give up. Luckily out of nowhere it started blowing the fuse immediatly after turning the bike on
(never did that before it would always run awhile) New ignition switch on the way. Perfect timing now that is 10 degress with snow and ice on the ground.
Thanks for all your help guys.
P.S. that f-ing bike is going to pay for this next spring with some serious beatdowns

 

[camms]

problem not found. only 2 things left ecu and wire harness. harness not available anymore! wtf husky

 

[DYNOBOB]

Hey cam and dynobob thanks for the responses. Here is what i know.

1. Bike is a 2007 TE610 5400 miles
2. Fuse does not blow at idle only under accelaration not at any specific RPM
3. Stator was replaced at dealer vr by me (was testing at high volts thought that had to be it)
4. Tried 20 and 25 amp fuses. Same result.
5. Cam 630 is different but if i had to guess it would be #8 on your picture
6. Bought it this year with 4500 miles ran f-ing awsome until this
7. Dealer is qlueless
8. Battery is brand new (il try one from one of my other bikes)
9. Ive checked every wire routing, wire harness 3 times cannot find anything

Here is what i dont know
1. Why did the bike die the last time and why will it not start now

Bike is back at dealer they offered to work on it for free because they thought it was the stator, replaced it charged me and that didnt fix it.
Cam i will relay your test to them and see what happens.
The most sickining thing about this is i am an electrican, That has provided alot of material for my riding buddies. Bastards!

Thanks again guys ill keep you posted, let me know if you think of anything else.

How high was the voltage w/ the old vr? Maybe it smoked something in the ecu? IIRC the bike would run at one point but won't run period anymore?

Where do you live?


.

 

[Rough Rider]

This thread is well timed, as my 06 SM610 started doing something very similar last week.

My symptoms of the issue are as follows:

1. Whilst riding the bike I noticed the speedo/gauge cluster going crazy with all of the warning lights randomly flashing. The speedo background then blanked out then started displaying random characters that changed and flashed. The indicators were also going crazy and flashing randomly without me even flicking the switch.
2. This only went on for about 10-15 seconds then all the lights and the speedo went blank
3. The bike was still running
4. I turned the bike off and it would not re-start
5. I found that the same main 15A fuse had blown
6. I replaced the fuse and turned the ignition on and the gauge returned to normal
7. I started the bike and when I gave it a few revs the exact same problem occurred and the fuse blew again.

I haven't had time to inspect it yet but will get onto it in the next few days. I hope to god that you find a solution soon so I know where to start looking

Just returned from a trip where mine did exactly the same thing, lost the speedo/gauge cluster, only the green headlight indicator and the green neutral indicator lamps stayed on. At the first overnight I found a 20 amp fuse was blown, I do not know which fuse it is as i did not have the manual with me. I changed the fuse and the cluster returned to normal (mostly the bright light indicator would not switch off although the lights worked correctly). Ten minutes into the ride the following morning everything dead again. I completed the ride and returned the bike home and have not even unpacked it yet. My bike is a 07 EFI bike, which I think is the 08 bike States side. Help would be appreciated before I start stripping (oh i did fit LED flickers which I could not get to flash correctly and a few months ago I lost the turn signal indicator on the cluster.)

 

[DYNOBOB]

thinking out loud here...

Will the bike start and run without the gauge cluster plugged in? If it will, run it that way for a while and see if it blows the fuse. Maybe a short in the gauge...

I just went thru a similar fuse blowing episode. Ended up being wires plugged into injector had rubbed on the injector rail and were shorting intermittently as I hit bumps. You may have something similar, but God knows where. On my 630 I think the main harness is pressed awfully tight to the frame by the rear of the fuel tank, I'm watching it for signs of chaffing.

Did you install a part with your blinkers to get them to flash correctly?


.

 

[Rough Rider]

thinking out loud here...

Will the bike start and run without the gauge cluster plugged in? If it will, run it that way for a while and see if it blows the fuse. Maybe a short in the gauge...

I just went thru a similar fuse blowing episode. Ended up being wires plugged into injector had rubbed on the injector rail and were shorting intermittently as I hit bumps. You may have something similar, but God knows where. On my 630 I think the main harness is pressed awfully tight to the frame by the rear of the fuel tank, I'm watching it for signs of chaffing.

Did you install a part with your blinkers to get them to flash correctly?


.

I tried two different LED relays but neither of them worked at all the blinkers just stayed on all the time. Just before I lost the gauge cluster the blinkers were working but the rate was much faster than in should have been. Without the guage cluster the bike ran 100% without even a hiccup, although I had no lights, brake lights horn etc (luckily I refuse to ride at night).

 

[camms]

Yea i tried running it with pretty much everthing i could unplug guage, lts, blinkers, you name it still blows the f@#ker. Its winter here now
so ive all but given up for now. Hurts my head to think about. Been riding all kinds of bikes for almost 30 years and have never had a problem this severe.
This is my first husky and i loved the bike but dont know if ill ever buy another after this.

 

[mvmac2]

My 06 te 610 had been blowing the main fuse periodically for a couple of years. I found this "thread" which motivated me to check all wires for a short. As I was looking with the ignition/lights on, I noticed the brake light was activated-bright. I stepped on the brake and the fuse blew. A quick search of the wires I found two that were sticking together. Didn't really look melted. But I could see a very small exposed area. I separated and taped the wires and no more blowing fuses. Btw, want to show the Buell headlight and custom Mask I made for the bike. View attachment 23222

This light is sweet!!