• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Electrical runaround 2007 TE 610

That's a great find. If I a finally reading the correct diagram, on the 07 the wiring is strange. It appears to have two power circuits, regulated and unregulated. The power from the regulator (Red Wire) only powers:
1. battery charging (the 15A fuse)
2. condensor
3. horn
4. turn signals & flasher
5. speedo

A short near any of these will blow the fuse.

The remainder of the power for the whole bike comes straight from the generator on the (Yellow wire) and is not fused anywhere. Not a very good design. Hope this helps. Cam.
 
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
 
problem not found. only 2 things left ecu and wire harness. harness not available anymore! wtf husky
 
camms said:
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.
Click to expand...


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?


.
 
What conditions/symptoms led you to beleive it was the ignition switch? Given numerous past issues with husky wires I would lay my bets on the wiring harness. Can you make the fuse blow without the engine running? It may be possible to unplug some stuff for testing. I'll bet you are not having fun. Cam.
 
zooker said:
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:(
Click to expand...

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.)
 
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?


.
 
DYNOBOB said:
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?


.
Click to expand...

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).
 
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.
 
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. image.jpg View attachment 23222

This light is sweet!!
 
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