New 2011 570 FS head light and tale light not working

Brought home my new 2011 570 FS last Saturday and have spent time this past week adding heated grips, fan, and a map switch.

Got things back together and now have no head or tail lights.

Map switch and fan plugged into the factory provided plugs, heated grips hot wire tapped into an unused "switched" power feed up front. Also, while starting to trouble shoot the issue I have disconnected my heated grip power "tap" just to make certain it wasn't the cause.

OK then, I noticed that fuse circuit labeled #3 in the 10A fuse holder box is dead, totally dead, doesn't matter if the key is on or not although the key switch should be on for this fuse to get power, and by dead I mean this is testing the fuse holder as well just to be sure that the fuse, while looking ok could still be bad.. is not the problem. From what I gathered this is the circuit (#3) that would power the lights.

As this bike is new, still haven't riden it yet I talked to the shop I bought it from and asked if the know 100% that the lights worked when I took delivery of the bike. They said that yes, that the lights were checked during prep.

Ok what to do now? While the owners manual is better than any bike I've owned in the past it has no wiring diagram. Now I see you have to buy the CD to get it, like I really want to wait on that to get here!

This is not what I had in mind for my first post to the forum..........

Help to diagnose this problem would be greatly appreciated as it basically sucks to spent 10K + on a bike that breaks before I can even ride it.

Is the bike running when you are checking for lights.if not try starting the engine.

The auxiliary circuits are on a power relay so they only get power when the bike is running. This prevents your battery from going dead.

I added heated grips to my 2010 FE450 but I wired them to fuse 4 - which is also blown on my brand new bike. I decided to use fuse 4 so that if (when) I blew a fuse I would not loose my headlight. I rode all day yesterday without the fan, horn (never use anyway), brake light, and grip heaters (which I wanted to use).

I am not sure of the specs, but it could be that the combination of your grip heaters and the headlight exceeds 10A. If not, then you probably have a short somewhere.

I suspect I have a short as well. I just need to hunt it down. Most likely it is the wires I added for the grip heaters, although I have read other posts of shorts in various places - but mostly from continual abrasion - and I don't think I have enough miles on mine to have a wire failure from rubbing.

I picked up fuse 4 power on an unused connector that sits under the battery. You have to take the tank off (or at least drop the rear end) to get to it. I routed my new wires along the same path as the main wiring harness - but it is really tight in there and difficult to get clearance around the tank.

Here are the wiring failures I have read about or suspect so far:

* The bottom rear end of the fuel tank (where the fuel pump is mounted) is really tight and can easily pinch the wiring harness. This is basically just below and in front of the battery.

* The harness could be rubbing on the rear shock chamber.

* The harness rubs on the motor mount ridge just in front of the shock.

* I have heard of wires getting melted by the exhaust header. I think it was the fuel pump wire in this case.

* I suppose a wire could melt as it routes above the engine and in between the radiators.

* It could rub on the steering stem - especially as the handlebars are turned stop to stop.

* The headlight shroud doesn't leave much room. It is possible that something got pinched when you put the shroud back on.

If you find it, please post your results. It may help others (including me) to find their electrical problems.

I should have also stated that the grip heaters are "tapped" into circuit 4, which make the, no power, issue for circuit #3 that much more frustrating.

Issue resolved!

I'll post pictures and what went wrong later today :mrgreen:

I found mine today as well. One of the connector insulators on my grip heaters slid down the wire when I installed the headlight shroud. The wire would then bounce and short against the bar mount. I am just glad I don't have to pull the tank off again!

So, when I went on a search for power for my grip heaters that was switchable via the ignition key I found a nice red wire that dead ended in a white plastic terminal, the other end of this terminal (quick connect type) was/is heat shrinked in a twisted fashion. Fine, I figured this was one of the many wires not being used, basically figured that for a different model of bike this terminal would be plugged into something.

What I have discovered is that this terminal is terminating the wires together, so when I pulled the pin out and cut the wire off the pin I was taking a wire that was actually being used. Thankfully I didn't trash the pin so I soldered it back on the wire with my grip heater wire and plugged it back into the terminal.

Problem solved.

I search the FAQ on how to post a photo without any luck so I hope this attachment works ok. The photo shows the terminal which is found near the clutch side fork leg.