Question about 1979 Harley Davidson XLH 1000 Sportster

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My relay switch keeps tripping and resetting when the key is on, resulting in a draw on the battery and funny running until the battery is dead. I replaced the key ignition but the problem is still there.

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You have a dead short somewhere in your wiring. You need to track down the short to resolve this issue. Start by determining which breaker keeps tripping. If it is the main breaker the fault will most likely be in the wires coming from the ignition switch the rest of the breakers. If it is the breaker with gray wire from the ignition switch it will be in the ignition/starting wiring. If it is the breaker that is connected to the gray wire from the ignition switch through a brass bridge bar the short will be found in the horn, turn signal, warning lights, or brake light circuits. If it is the breaker that is connected to the green wire ignition switch it will be in the running lights circuit.

Posted on Jun 29, 2009

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Plz relay wire joint properly

Posted on Jun 15, 2009

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Good info on the PATS / theft light. Looks to be the PATS / HEC operation is functioning correctly

The Fuel inertia switch only cuts power to the fuel pump, so if tripped, the truck would have a crank no start issue. Do you have a crank no start, or no crank issue.

To reset, just press down on it. To check if the switch is tripped, check for power at the connector to the fuel inertia switch

Engine compartment fuse # 10 ( 20A ) to the fuel pump relay -> Dark Green w/ yellow stripe wire to the fuel inertia switch -> pink w/ black stripe wire to the fuel pump module.
Check the pink w/ black stripe wire to ground with a meter for power, with the key in the run position.

If you turn the key from off to run ( do not start ) you should hear the fuel pump cycle ( hum, then turn off ).

Could be an issue with the fuel pump relay ( my '01 had a crank no start at ~ 35K miles, bad fuel pump relay ). I proved this out ( after a stupid ID10T error in my diagnoses process ) by jumpering the normally open contacts in the fuel pump relay socket, and then installing the trailer tow reverse circuit relay into the fuel pump relay socket ( same full size Ford Relay ).

Jumpering the fuel pump relay in the relay socket ( remove relay and use jumper wire ), red line
sscullys_16.jpg

If you have a no crank issue, could be the DTR ( Digital Transmission Range ) sensor on the driver's side of the trans is out of alignment.

Check the start motor relay ( on the firewall on the passenger side ) for power on the Tan w/ Red stripe wire when the key is in the start position ( this is from the ignition switch through the DTR when in park or neutral to the starter motor relay ).

You can test another route, turn the key to the run position, and apply power to the Tan w/ Red stripe wire on the starter motor relay in the engine compartment on the firewall. BE CAREFUL, the motor should turn over, keep clear of moving parts.

Post back a comment to this problem with the results of the testing.

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Hi.. after you do this step come back and rate as fixya. OK..

Turn the ignitio key to run position
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Remember all this steps with the trip botom pushed. OK.

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