nc30 starter relay fuse blowing

[brido]

Hi all went out for a ride today and on the way I flashed my headlights to let a motorist change lanes, when I did this the motor and all electrics went dead, when I coasted in and had a look about noticed that there was no power. Got the seat off, and checked all the fuses, all were ok except the starter relay fuse which had blown, tried the spare and it did the same, so has anyone any ideas

[Neosophist]

short circuit somewhere!

Is it just when you flash the high beam?

The high beams on a relay so check around there for wiring problems.

[brido]

I dont know if it was because I flashed the high beam or not but it did happen at the same time, when I put the spare fuse in it blew straight away and I didn't flash the high beam then

[MexicanGringo]

Like Neosophist suggested its a likely short, theres a live from the 10A fan/tail/horn fuse to the lighting controls, possibly somewhere along that live.Also possibly at the high beam relay terminal on the right hand side. Does the fuse blow with lights off as you turn the ignition? Or only when lights are turned on?


*EDIT* actually if there was a short on that 10A live, that fuse would blow not the main fuse. The short must be before the other circuitry and thus the other fuses. The cable from the main fuse goes to the ignition switch, from there to the 20A headlight fuse, and also to the 10A tail fuse as mentioned above, also to the reg/rect

[brido]

The fuse is blowing when I am putting the connector for it back together again, as soon as it connects, the fuse blows, I don't even get a chance to turn on the ignition or lights:?

[MexicanGringo]

That means a wire/connector after the fuse is shorting, touching the frame probably, or another circuit. It has to be before the ignition switch then, so either on the way to it, or on the way to the regulator/rectifier.. Unclip the connector that feeds to the ignition (3 wires) and check the contacts and wires, do the same for the reg/rec connector (5 wires).

Its a 30A fuse i think, u replaced with the right one?

[Neosophist]

If it's blowing without the ignition on that should be easy to find.

Most things run through the fuse-box aso you only have to follow the wires from your 30A main fuse.

You have a live wire touching the frame somwhere... The R/R unit connects to solenoid that houses the main fuse so try looking at those wires.. won't take you long to find that one :)

[brido]

Right I started with the reg/rec and I couldn't see anything wrong with the wires, so I unplugged the reg/rec and put in a new fuse, it didn't blow , turned ignition on and everything works fine , plugged the reg/rec back into the loom and still everything ok , until I touch the frame with the reg/rec and then it started sparking, so do you think the reg/rec is the fault?

[MexicanGringo]

It doesnt look like the metallic heat sink backing to the reg is supposed to conduct, theres a ground shown on the schematic connected to the reg but its shown far away, so if the metal back sparks when touching the frame then somethings gone wrong inside..

Try running the bike with reg plugged in but not attached, for a short period, & test voltage @ 5000rpm over battery, should be 13.5 - 15.5V, if its way out then the regs def gone

[brido]

voltage at battery @ 5000rpm is between 14.45 to 14.50 volts and the reg/rec is really hot to touch, is this normal??