Here we are again with an electrical problem. I was riding my bike home the other day and I noticed my running lights were not working. I figure this shouldn't be a big problem, HA! First thing, when I tried to pull the connector apart from the wiring harness from the relay the pins pulled off the ends of the wires, lousy crimps I muttered. Soldered them and put it together, no lights. Messed with the connectors and changed to a different style, again, no lights. Removed the entire light bar and lights and placed on bench, hooked up 12v, lights. Went to the end of the harness from the relay and 12v. Hooked them together and NO LIGHTS!
Scratching my head I installed a mating plug on the harness, like the one on the light bar with a couple of pig tails hanging out. Hooked up a meter and turned on light switch, 12v on meter, now I ran jumper wires from the ends of the meter leads to the tips of the connectors going to light bar, voltage dropped to zero. OK I have a current problem. Pulled the tank to check harness from relay, opened the fuse holder and looked at fuse. Looked good, not blown, it was read 12 v through the fuse. It was a 15amp fuse on a approximate 10 amp draw, should have been OK. Looked for a new fuse, didn't have one, but I had a 20 amp one. put it in the circuit, ran the jumpers again and LIGHTS.
Fuse that looked good, had continuity, was still bad. Took it apart, the connection on the inside of the end cap was broken and just touching the cap enough to give you a voltage reading, but not good enough to pass 10amps of current.
