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Old 4th September 2021
45Brit 45Brit is offline
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Default Complete cut-out while riding

I was riding my 92 XL when the whole electrical system shut down. I coasted to a stop and after a few clicks from under the seat, the horn and lights returned. I left the bike and fetched my trailer, so after standing for half an hour the bike started first try. I assume the main circuit breaker had tripped and then reset itself - but why? I had a shovelhead once which would occasionally do it, I never worked out why. This bike is normally very reliable.
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Old 4th September 2021
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The circuit breaker trips when there is a overdraw of current. Look for a short. If all wires and components look good replace circuit breaker.
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Old 5th September 2021
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Default

The input side of the main circuit breaker is fed power from the battery (RED wire).

The output side of the main circuit breaker (RED wire) goes to the keyswitch input (there is also the output from the regulator (BLACK wire) on this side of the main circuit breaker).

Both output sides of the keyswitch go back to the buss-bar on the other three circuit breakers.

I would trace down the wiring from the main circuit breaker to the keyswitch and then back from the keyswitch to the buss-bar of the other three circuit breakers to be sure the wire looks good.

Then - Do you have more than a simple key ring on the key? Other keys? Other items on the keyring?

Heavy items hanging on the key can cause the keyswitch (internally) to fail. It flaps in the wind and stresses the internal contacts. There have been a number of threads about failed keyswitches.

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Old 6th September 2021
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My 1991 had a faulty main circuit breaker. There was a recall notice about it years ago and I replaced it with a new one. Never a problem since.

John
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Default

Well, i had the same issue this week. For a while i'd mounted a navigation system, with an usb cable attached to optimate usb kit. All seems to work well for a year or so. But now for 3 times this week the engine stopped while riding, and the electricity went off. The first time i fiddled with the contact and the kill swtch and got it going. The second time i called the motor help, and after a long starting proces it started. The third time, i eventualy i disconnected the navigation system and it went on with a small bang.. So, fot me it think its an usb electricity problem. forgive for my strange expanation, but im dutch :-) and for breaking in at your post..
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