electrical short somewhere ?

[Guest]

I have a 1981 gs750e. I first noticed the problem when the headlight fuse blew. I changed the fuse, and ran the bike a few days, when it blew again. ( when the headlight is on ). Upon investigating further, besides the headlight circuit getting hot, at the fusebox, I, also found that the ignition circuit also gets hot when the bike is not running, with the key on, and the kill switch is in the "run" position. Can the problem be deduced from this information? I did, recently, replace the reg/rect. with the "SH775" , and improved all the grounding points, per directions from the forum. Although, I'm only fairly electrically ' savey ', I thought I would put this out there, for possible help in the right direction from someone who is. I guess i'll have to start isolating circuits, and look for poor grounds, or chafed wires. Because two circuits are 'heating up' (headlight and ignition), I thought this might be indicative of the problem area. P.S. although the ignition circuit gets hot, it never blew a fuse, and the bike does run well. Thanks, Skyhawk.

[Steve]

Your ignition getting warm is normal, and has nothing to do with the headlight circuit.

Warmth happens in an electrical circuit when there is resistance. Sometimes the resistance is intentional and desirable (headlight bulb, for instance), but not so welcome at other times (wires, connectors, etc.). If your headlight circuit is getting hot in the fusebox, check for dirty connections. Don't just look, please actually CLEAN the connections, just to be sure. Also follow the wiring harness to the front of the bike, inspecting it anywhere it crosses the frame. Over the years, with all the flexing it does, it might have worn through the insulation and is touching the frame occasionally, which would blow the fuse.

.

[tom203]

Does this bike still have "on/off" switch in left control switch?
Out of curiosity,did you wire the SH-775 output into harness, or direct to battery via in-line fuse?x

[ray c]

Yes, there is an on/off switch for the headlight on the left handlebar control, and I wired the reg/rec. to the original system, (fuesbox).

[posplayr]

Yes, there is an on/off switch for the headlight on the left handlebar control, and I wired the reg/rec. to the original system, (fuesbox).

There were only two options as Tom asked; Your answer is not really clearly identifiable as one of those. Have you discovered a third? We ask as that could explain your blowing fuses.

[ray c]

I'll check the bulb wattage, although, I know it's been in there many years, without a problem. I guess i'll just start at the beginning and check all connections and wire conditions throughout the headlight circuit, as Steve suggested, and hopefully see something, and let you guy's know how I make out. Appreciate the help everyone, Thanks, Skyhawk