I'm stumped on electrical problem

while riding last night my 2000 1500i just quit at a stoplight. Hauled it home and have it tore all apart, keeps blowing the main 30 amp fuse. Bypassed battery, cables, ignition switch, clutch switch, took tank and side covers off and unplugged all connectors and relays, no matter what it pops the main fuse instantly. Even took the headlight out, I don't know what else to check. What am I overlooking here?

[tomm]

Hi Randy,
I've never done any electrical work on these bikes, but I have on other bikes. The procedure is pretty standard. Suggest you buy yourself a digital ohm meter at your local hardware store if you don't already have one. They're pretty cheap.
Then since you're blowing the main fuse instantly, you can safely assume that a hot wire is dead-shorted to ground somewhere.
Take the fuse out and disconnect the battery. Turn everything off, take out bulbs, all other fuses, and unplug as many connectors as you can. You're trying to isolate the wiring into as many discreet circuits as you can. Then start taking resistance measurements from various hot points back to ground. A wiring diagram comes in real handy here. With everything off and unplugged, you should be able to eliminate some areas of wiring. Most of your measurements should show open from hot to ground. You're looking for one that shows short to ground. That's where to start looking for a shorted component, a wire with no insulation, etc. Just don't get misled by a short reading through a light bulb or something like that.
Tom

[ringadingh]

It sounds like you have a short circuit somewhere, probably a wire that has chafed through and is grounding to the frame somewhere. It could also be the starter or a switch shorting also. Try to disconnect things and see if that stops the fuse from blowing. Are there any of the 10 amp fuses blowing? as this would help narrow it down to a individual circuit. I know from experience that problems like this can be very tedious to repair.

[blowndodge]

its a hot wire hitting metal somewhere....

None of the other fuses are blowing, only the 30 amp main. What all is on that line if not blowing out the others, anyone know?

[chuckster131]

Check where the harness goes up over the rear rocker cover. Mine wore right there and was blowing the main 30amp fuse too.

Originally Posted by randy3825

None of the other fuses are blowing, only the 30 amp main. What all is on that line if not blowing out the others, anyone know?

Rear Rocker Cover? Not sure where you are talking about.

[chuckster131]

Give me a shout 517-474-2663

Originally Posted by randy3825

Rear Rocker Cover? Not sure where you are talking about.

[chuckster131]

Randy,
Any luck?

[macmac]

I agree a chaff in the harness some where, probably right where Chuckster said to look.

I would get to the ECU and unplug it right after I yanked the battery which is cake on a 1500.

Then you can wiggle and fiddle all you like blowing fuses like a mad man, untill you learn the easy how to of a ohm meter which is A1 the right way when you have this particular problem.

[zoom45]

Check the harness on the left side of the bike where it comes up by the front forks (in front of the tank). It makes a bend there and will move when turning back and forth. If your harness flexes at that location it could rub a wire.
Zoom45

Originally Posted by chuckster131

Randy,
Any luck?

I just got home from work and sun is setting, tomorrow I get home about 2:30 and will go straight to pulling the main harness out and checking it over.

Ok, yesterday I got the wiring harness out from the frame, inspected it and found nothing in the obvious, skinned back ALL the outer tape insulation and carefully inspected. Followed cable down and took off the side cover for the trans and shaft area, unplugged all the connections down that way, hooked up juice and no blown fuse, so concentrating on that area one by one I plugged connectors back together, when I plugged back the left side regulator (mounted under the radiator, there are two, left and right) the fuse popped, tried 3 different times, this was the only thing plugged in the circuit. Took it off and went to the Dealer. said it's a voltage regulator. both are the same part number and would have to be ordered for $162. So I went back home and plugged the harness into the right regulator and fuse was fine, plugged the left one back in and still all good. SO apparently the problem is actually in the wiring someplace, will tear back into this evening after work.

[kenb]

Are you using a wiring diagram/service manual and a DVOM? Very valuable tools in this kind of situation. From your descriptions, it sounds like you are in "tear down and inspect" mode. No mention of using a meter or diagram.

[tomm]

Hi,
Hopefully the attached is readable. Steps for checking out a regulator.
When you plugged it back in and the fuse didn't blow, did you reattach it to the bike first. If the regulator is internally shorted to the case and the case isn't attached to the frame, it could still be bad and not blow the fuse. All depends on how it's wired inside.
Either way, it sounds like you're narrowing it down. Hope it's just wiring. Lot cheaper.
Tom