Tracking a blowing signal fuse

[Guest]

Hi guys - grab a coke & popcorn please and read on -

Why is my turn signal fuse blowing suddenly? I've had my '83 GS1100ED for 3 years, with no issues - not one.

Story - my son-in-law was riding it to work, and the taillight bulb blew out.

He replaced the bulb, and he said the bulb was stuck so tight the socket was twisting when he got the bulb out.

He then washed the bike.

Then the signal fuse blew. He replaced it, and it blew again.

That's when I put in a fuse, and it blew, pop - as soon as I turned on the key.

So I stuck a 20 amp fuse in it, so I could maybe troubleshoot it, and I measured the voltage, and I was pushing over 18v at 3000 rpm's.

So I replaced the voltage regulator, and was rewarded with a nice 14.3 volts at 3000 rpm.

But the signal fuse blows, and if I put in a heavier one, the main fuse blows. I pulled apart the back taillight socket, and no twisted out or frayed, or hot-looking wires.

So I've pulled off the tank and bodywork, and intend to go out tonight, pull the headlight, and start unhooking harnesses until the fuse doesn't blow. I'm not a big fan of my fathers philosophy, where he would put in a big fuse and wait for something to get hot.

Am I overlooking an obvious starting point?

Any advice is appreciated.

Thanks - Eric

[rustybronco]

Is the bulb that was installed the correct bulb?

[Montanaman]

Bulb was correct -

So I pulled all the bodywork & tank, and I took out all the signal bulbs, POP - blew a fuse.

Then I started unhooking a connector at a time, and each time I'd put in a new fuse, and POP - off to the next connector.

Right up until I was almost out of fuses, and I unplugged one of the instrument clusters - then no POP.

It turns out that the big cable inside the instrument cluster had rubbed through the insulation where it was folded over, and was arcing to the main steel support.

So I insulated it well, and now tonight I get to put it back together.

[posplayr]

Congratulations, hopefully it is clearer why attention to wiring is so important. Wiring is robust if you dress it so it does not wiggle with vibration and does not rub on something to cut through the insulation.

[Montanaman]

At least I found out about the blown voltage regulator before it really started frying things!