74 RD350 new wiring harness getting hot

[__Treetop__]

Nearing the end of my 74 RD350 build and the wiring is causing me fits. Definitely my weakness when it comes to wiring. I installed a new wiring harness from HVC Cycle and when I turn the key to position 1 the headlight works, low and high, and the horn works but the brown wires are getting too hot and starting to smoke. I've checked and cleaned the grounds at the battery terminal and under the tank and that hasn't helped. Anyone seen this before? Any ideas would be appreciated.

Treetop
ATL GA USA
1974 RD350

I



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[m in sc]

start unplugging stuff. remember, theres 2 browns, a dark and a lighter. darker is TS where lighter is switched 12v.

look for frays in the gauge lights and the bucket.

unplug items and individually re-connect them to find the draw and the short. also, switches can be a culprit.  and those emgo coils.. make sure they arent causing issues. the connectors can rub the frame.

[__Treetop__]

All good advice, thank you. I will check all those points. Yeah it's the lighter brown 12v switched that's getting hot. I don't have any of the wiring for the speedo tacho lights plugged in but I may not have wrapped those bullets in tape either, so they could be the culprit!


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[AAAltered]

Like Mark said, there are two "browns".  One run is labeled "Br" for brown and the other "Ch" for chocolate.

I would disconnect anything brown/chocolate in the headlight bucket and recheck each connection.  Hot as in smoking is really no good and can't go for very long before stuff gets ruined.

[Striker1423]

Yea, smoking means battery is finding ground through those wires directly. At minimum you'll compromise the shielding on the wire, at worst you'll start a fire and/or burn yourself.

[Inov8]

start unplugging stuff

You can also do the reverse. Start with everything unplugged except for grounds. Begin adding components to the system one at a time until plugging something in creates high amperage load. This method allows you to take your time and not worry so much about burning anything. Once you identify and eliminate the short circuit I recommend testing the resistance of the affected wires. A quick online search will give the desired resistance value for the wires based on gauge and length. Replace any wire you find to have an incorrect or floating value.

Great looking bike; by the way. Please post more pics or even consider adding a build thread. Thanks

[m in sc]

thats what i said.. but i didnt phrase it till the 3rd sentence. lol. My bad.

it IS a great looking build. really good. I agree, we need details please. 

[Inov8]

Sorry Mark. I did wonder if that's what you meant. No offense intended. Who, me, oversimplify? You must have me confused with someone else. 8)

A lot people seem to be intimidated by electrical issues so perhaps I feel like explaining things the way I do helps remove some uncertainty.

I'll just shut up now and go back my Crayons and coloring book.

[m in sc]

you phrased it way better than i did!! 

[Inov8]

I feel like I owe you a beer.

[__Treetop__]

Thanks for the replies. I will try that method of unplugging and leaving the grounds on and plugging back one at a time and get back with results


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[forexer]

you can also try and find it by pulling one fuse out at a time until you find the problem circuit and then once you find the problem circuit you can troubleshoot the individual components within that circuit.

Good Luck!

[rodneya]

you can also try and find it by pulling one fuse out at a time until you find the problem circuit and then once you find the problem circuit you can troubleshoot the individual components within that circuit.

Good Luck!

There is only 1 fuse

[m in sc]

yup. only 1.

[rodneya]

yup. only 1.

Makes sure that any short in any part of the harness stops you dead in your tracks, usually right in the middle of traffic..