I have limited electrical experience on the Vulcan but I did find out that my main fuse blew out several times because when I switched from the stock single round headlight to my present dual rectangular headlights the wires were exposed before I finally used plastic looms (covers) I had a pinched wire at the fork lock mechanism. If I made an extra sharp right turn it would blow the fuse. It took a bit of time to finally get the scenario figured out and then come up with the exact diagnosis visually before the five minute repair. I still carry three five packs of main fuses in the tool box along with one pack each of the others. Check all your connections and make sure your wires are not getting pinched behind the headlight and in front of the fork. You need to figure out the actual scenario of when exactly the fuse blows such as turning, using signals, brake lights, etc. From that I am sure you may figure out a possible cause and only need a quick fix similar to my situation. Good luck.Is your volt meter still working? I tapped in to the left marker light and after about 35-40 miles it blows the main fuse. I am using the Kuryakyn volt meter . This has happened 3 times it is disconnected at this time. Any thoughts.
I am using a battery monitor as opposed to an actual voltage meter, so I opted to tap into the front running lights in the headlight bucket. The difference in voltage from the battery to the front lights were not an issue for me.That is a good idea with the relay. Thanks.
I am more concerned with a consistent reading as opposed to an extremely accurate one.
I want to know if it simply stops charging, or drops suddenly.
If I were to guess, I lose about .5 volts at the headlight accessory wire.
This is with a simple $20 volt gauge though.