Constantly blowing starter/ignition fuse??!!

[Gimly56]

My bike started up fine the other day...then it died & it wouldn't start at all. Not even an electrical click from the solenoid. Dead!!

Eventually I found that the starter/ignition 10A fuse was blown



I replaced the fuse and the bike still wouldn't turn over. Eventually I replaced the CDI and the bike started again!!



BUT...the bike died AGAIN and I checked the fuse box and sure enough I'd blown that starter/ignition fuse again???

I'm hoping I haven't popped my reserve (last) CDI unit again???!!

Help me diagnose this electrical gremlin please?!!!!

[Gimly56]

Could a faulty regulator/rectifier cause this issue???!!

[tanuki]

unlikely.....whats the condition of the starter relay is there any signs of melting?

I ve known dodgy starter relays to really odd things.

[Gimly56]

Starter relay looks fine. No melting at all!?

Ive got a spare relay...might replace it again and see what happens??....it[*]s a worry because Im gambling with the ECU now!

[Gimly56]

Replaced the starter relay..AGAIN....and started it up and it just blew the fuse after 10 seconds.

So this time I inspected the regulator/rectifier.....knew things were suspicious when I couldn't get the plug off the rectifier...and when I finally got it apart this is what I discovered!!



So I think I have discovered the issue!! Haha.

I'm thinking about buying one of the heavy duty models off GF but the actual plug itself is fried and melted as well?? Anyone know how to find a replacement male plug??

[vfrman]

You can get the plugs on eBay, but I opted to use a sealed plug similar to the ones found on my Ducati.

[Gimly56]

Thanks, I opted for a Graeme France version.