[Don_K]

Friends,
2003 GL1800, 37000 miles. Pushed "cruise on" button and no "cruise on" light. Drove for a while and killed the battery. Checked fuse 19 and sure enough, it was blown. Replaced fuse and again pushed cruise on button. Fuse blew again. Got the bike home and checked cruise wiring at the switch and on the handle bars and cannot find a short. Took off the top shelter and can find nothing out of the ordinary. The fuse doesn't blow if I don't push the "cruise on" button, so it's obviously in the cruise wiring somewhere, but where? From searching a few posts it seems I'm not the only one that has encountered this issue. Any ideas on a possible location for the short? I've checked the areas that some of you have suggested, but no joy. Any help is appreciated. - Don

 

[CAWing78]

Re: Fuse #19 blown

Looks like you'll probably need the service manual with the wiring diagrams to track down the culprit. If you've installed some aftermarket gizmo lately you might start there.

 

[Don_K]

Re: Fuse #19 blown

I haven't installed any aftermarket items with the exception of a windshield and that was months ago. I used the cruise a few weeks ago for an entire day without issue. I have the service manual and I'm proceeding with the flow chart in the electrical diagnostic portion of the book. Basically, it says to replace the fuse and try to use the cruise again, if the fuse blows again, check the cruise control wiring for a short. According to the service manual the cruise wiring is interfaced to many other components including the ignition. Everything else works fine, so it's rather confusing. This will be quite an undertaking if I can't find someone who has had and resolved the problem previously. I'm hoping for an "Oh yeah, check this area" kind of thing. - Don

 

[CAWing78]

Re: Fuse #19 blown

I have the service manual and I'm proceeding with the flow chart in the electrical diagnostic portion of the book. This will be quite an undertaking if I can't find someone who has had and resolved the problem previously. I'm hoping for an "Oh yeah, check this area" kind of thing. - Don

I know what you're saying. I hope someone will chime it with a solution. Good luck.

 

[Tawni]

Re: Fuse #19 blown

Also for future reference.

if that ever happens on the road , replace the fuse and don't use cruise.

I am told that if the cruise fuse blows you wont charge the Batt.

 

[DrtiBird]

Re: Fuse #19 blown

I haven't installed any aftermarket items with the exception of a windshield and that was months ago. I used the cruise a few weeks ago for an entire day without issue. I have the service manual and I'm proceeding with the flow chart in the electrical diagnostic portion of the book. Basically, it says to replace the fuse and try to use the cruise again, if the fuse blows again, check the cruise control wiring for a short. According to the service manual the cruise wiring is interfaced to many other components including the ignition. Everything else works fine, so it's rather confusing. This will be quite an undertaking if I can't find someone who has had and resolved the problem previously. I'm hoping for an "Oh yeah, check this area" kind of thing. - Don

Don,
The only thing that comes to mind is the wiring in the handlebar area. Some have found wires pinched around the switch area. 8)

 

[Joe In Calif]

Re: Fuse #19 blown

I had that happen on my 02 about a year after I had the frame re-weld done. Turns out it was the main ground (located under the fuel tank) was loose. The shop that did my frame re-weld did not tighten it up properly and it came loose causing a feed back when the cruise was set. Took another shop $500.00 worth of labor to find this out. Took it to the shop that did the frame re-weld West Coast Motorsports in Perris, Calif. and try to get them to reimburse me for the repairs but they said they only guarantee their work for 30 days!! I said it's a good thing you guys didn't change my tires and one fell off after 31 days! I never went back there again. And if that fuse blows your battery will not charge.

 

[RogerB4]

Re: Fuse #19 blown

Remove the wire tray's on the bottom of the handle bars. and then install a new fuse and see if it blows. If the fuse does not blow it is probably in the wiring to the cruise safety switches on the front brake or the clutch. You can remove a lot of tupperware before you find this out. Don't ask how I wasted 2 days chasing this problem.
RogerB :x

 

[Don_K]

Re: Fuse #19 blown

Guy's
Thanks for all the helpful info. I've checked all the wiring under the handle bar covers and found nothing. I checked voltage on the #19 fuse holder I have batt voltage on the right side and if I check from the left side to ground there is no continuity. If I push the cruise button I get continuity to ground from the fuse left side. It seems to me that the left side is grounded and shouldn't be??? I disconnected the switches for the clutch and front brake and still the same problem. I'm starting to wonder about the ground under the tank? Again, thanks to all of you for your suggestions.
This has me pulling my hair out, and I've none to spare......... - Don

 

[Jon]

Re: Fuse #19 blown

Probably 95% of the reported 'Fuse 19 Blows' messages here are due to shorts in the wiring that runs up the right handlebar to/from the switch cluster. This wiring is commonly pinched when installing aftermarket accessories, heated grips, risers or anything that might disturb this wiring and it doesn't have to happen immediately after this work has been done - it may take time to wear through the insulation to a point that will cause the wiring to short to ground.

Since you said that you only blow the fuse when the switch is pushed, the wiring from the fuse to the cruise relay, from the relay to the Green plug under the RH pocket and up to the switch is clear. The question is whether the short is in the wiring that leaves the switch and runs down the handlebar, or further downstream.

I would start by unplugging the Green connector under the RH fairing pocket and check for a short on the Green/White on the bike harness side of the connector. This is the wire that feeds the Cruise Cancel switches on the throttle and the rear brake before it connects to the Cruise/Reverse Control Module.

The next step is to check the Blue/Yellow wire that leads to the handlebar - this is the wire that provides switched power to the bike to indicate that the cruise has been turned on. If this wire in the half of the connector that feeds the handlebar is clear with the switch in the cruise OFF position, then there is no ground in that portion of the wiring. If there is a ground on this wire with the switch in the ON position, then the short is in the White wire that provides power to the switch.

If both of these are clear, then there should be a short on the Blue/Yellow wire on the bike half of the Green connector. This wire takes the 12V switched power from the Cruise Enable switch feeds the clutch cruise switch on the left handlebar.

Good luck...

 

[Don_K]

Re: Fuse #19 blown

Jon,
Thanks for the help. I have continuity to ground from the orange, blue and green w/white on the bike harness side of the system. (It's the 12 pin connector. This plug feeds the left handlebar harness.) I have no ground continuity to any terminal on the handlebar side of the harness plugs for the left or right side so it doesn't seem to be in the handlebar area.
I don't have any wire colored blue w/yellow on either bike side or handlebar side of the harness.
I disconnected the switches on the rear brake but continuity was still on the green w/white wire at the bike side harness plug. What do you think??

Thanks to everyone for staying with me on this. - Don

 

[techdude2000]

Re: Fuse #19 blown

The wires you are looking for from the handlebar switches are Black and yellow, not blue and yellow. If you check the continuity from these wires to ground you might find a short. If not, then unplug the cruise/reverse control module under the shelter and try a new fuse again.

 

[Jon]

Re: Fuse #19 blown

Sorry about that - I always get those two mixed up...

 

[Don_K]

Re: Fuse #19 blown

I have continuity to ground from the black w/yellow wire coming from the left handle bar. Is this from the clutch switch?
-Don

 

[Jon]

Re: Fuse #19 blown

Yes (at least according to the manual for my '02).

If you don't have a ground in the Green/Blue wire, and nothing on the bike harness connector for the Black/Yellow wire, you know the short is in the wiring between the Green plug under the pocket that runs up the handlebars to the switch.

 

[techdude2000]

Re: Fuse #19 blown

I have continuity to ground from the black w/yellow wire coming from the left handle bar. Is this from the clutch switch?
-Don

Yes, but keep in mind that the black/yellow wire is connected to the clutch cancel switch, the front brake cancel switch, the set/decel switch, the resume/accel switch, and the cruise control module. A short to ground on any of these wires will give you the short everywhere along these wires. If you unplug the connector C22 under the right fairing pocket it will disconnect about half of the circuits.

 

[Don_K]

Re: Fuse #19 blown

I have no continuity between ground and the blue w/green wire. I have continuity between the black w/yellow and ground in the harness that goes to the handlebar. I have unplugged all three connectors under the right fairing pocket (2 green 1 blue) to eliminate the main harness from this test. (The black w/yellow seems to run to a few places) I get no continuity to ground on the black w/yellow wire in the main harness with the green plug disconnected from the handlebar portion. - Don

 

[Jon]

Re: Fuse #19 blown

... I get no continuity to ground on the black w/yellow wire in the main harness with the green plug disconnected from the handlebar portion. - Don

Then your ground is obviously somewhere between the Green connector and the cruise control cancel switch. Time to pull the cover off the left bar and to remove the gauge cover to follow the harness.

Do you have risers installed or any other aftermarket items on the left bar?

 

[Don_K]

Re: Fuse #19 blown

Jon,
I have no accessories on the bars at all. I'll be out of town tomorrow so I'll get back to it on Monday. I really appreciate the help. I'll be sure to update the board on what I find. Thanks again to everyone for the help. I think we've made some progress and at least eliminated some possibilities. (FYI - I did lift the fuel tank to check the main ground as one person suggested, however the bolt was tight the connections clean.) What a nightmare. - Don

 

[Waldo]

Re: Fuse #19 blown

Pay no attention to the text in this pic, it's not relevant. The blue dotted line is where that left switch harness goes around the steering knuckle. Lots of "rubby" areas there under the top bridge.