Main Fuse Continually Blowing

[tom203]

While you're checking stuff, make sure you pull tank to inspect coil wiring.As mentioned, break up this ignition circuit into seperate pieces till you find the short- the kill switch is a likely candidate.

[bakalorz]

Welcome to the forum, James!

I have a 1982 GS1100GK that does exactly the same thing. The prior owner told me he had been riding the bike regularly until one day when it stranded him at work. I haven't had a chance to do any diagnostics on this bike, but when I unplugged the stator / R/R from the system I was able to start and run the bike without any problem, and all the other electrical components appear to be working. Obviously the bike will only run as long as the battery is in a good state of charge, but at least I was able to tell that the bike was in good mechanical shape overall.

I still don't know whether I have a bad R/R, a bad stator, or both (because this was bought spur of the moment and isn't my rider) but I figured my experience might help you narrow down the source of the trouble with your bike. If the bike runs with the charging system disconnected, you can then run through "The Stator Papers" to further narrow down which component has failed. The Stator and R/R systems are notorious troublemakers on the GS's, so I wouldn't be surprised if that's where the problem is.

There are far more experienced problem solvers on the forum who will, no doubt, be along shortly to provide more assistance if you need it.

Regards,

FWIW,

For the situation you describe, I would suspect the R/R itself or the wiring between the main fuse and the R/R.

The diodes in the R/R should isolate the fuse from a short in the stator or the wiring between the stator and R/R.

[Planecrazy]

FWIW,

For the situation you describe, I would suspect the R/R itself or the wiring between the main fuse and the R/R.

The diodes in the R/R should isolate the fuse from a short in the stator or the wiring between the stator and R/R.

Thanks for the insight! I've been meaning for some time to substitute in another old R/R (off of my '83 1100G) to see if the fuse stops popping, but simply haven't had the time or motivation to dig out the GK from what surrounds it in the garage, hehe! If the "G" sells soon I'll be more motivated to start digging in to the GK and getting it going.

The old R/R isn't regulating properly (wasn't charging the battery) when I took it off the bike and replaced it with a Honda mod, but it should be sufficient for narrowing down the fuse issue. Once I'm down to just one bike (or have cleaned out the garage enough to have space to work on both) I'll post a thread with progress updates...

Thanks again!
Steve

[tom203]

FWIW,

For the situation you describe, I would suspect the R/R itself or the wiring between the main fuse and the R/R.

The diodes in the R/R should isolate the fuse from a short in the stator or the wiring between the stator and R/R.

Say what? I thought he said he traced it to ignition fuse.

[Planecrazy]

Say what? I thought he said he traced it to ignition fuse.

Tom, bakalorz was responding specifically to my issue on the 1100GK that I mentioned mid-thread (not James' issue, which as you mentioned James has been narrowing down). That's why he quoted my post before responding...

Regards,

[bluewool]

I had a similar problem on Friday on my 1150 (which I originally attributed to Nostradamus, I have since reconsidered) I traced it back tentatively(I have yet to test ride it) to a chafed harness, and cracked wiring on the gear position indicator switch down by the final drive.

[tom203]

Tom, bakalorz was responding specifically to my issue on the 1100GK that I mentioned mid-thread (not James' issue, which as you mentioned James has been narrowing down). That's why he quoted my post before responding...

Regards,

Thanks, I have trouble multitasking!

[JamesH]

Update:

I believe I have tracked down the problem thanks to those suggesting to check the kill switch. Upon pulling the switch housing I discovered one of the O/W wires had been smashed by the metal cover plate for the switch, and was probably grounding out HARD on the handlebar...
I'm going to repair this and see if that was the problem!

[salty_monk]

That should do it... that's exactly what happened on my bike

[GearHead]

Attempting to revive this thread, I put a donor harness and fuse box in my 82glz and when I connect the battery the main fuse blows right away, I have already tried removing all other fuses and disconnecting the rectifier any suggestions ?

[Who Dat?]

... any suggestions ?

Just one. Start your own thread, rather than digging one up that is TEN YEARS OLD.