My bike blows

[Chris861]

fuses.   I know there are several posts on the subject already (I have already searched) but I can't find any that exactly fits my problem.  I went to class yesterday and came home and as soon as I turned in the driveway, my bike instantly quit.  It never sputtered, it just quit.  I checked the fuse and it was blown, so I replaced it and it started fine.  Went for a drive, went to wal-mart and got gas and it started back up fine.  Parked and went inside for 10 min. and when I came back out and turned the key, the lights and stuff wouldn't come on and it had blown again, so I replaced it and made it all the way home.  I've started it up a few times to test some stuff and it hasn't blown YET.  The battery is putting out like 12.3 volts (not started) and closer to 13 with it running and I checked the three yellow wires coming from the engine (which I assume is the stator) and it is putting out about 16-18 volts.  My only guess is the rectifier and I'm not exactly sure how to test it.  If thats what it is, anybody know where I can find one pretty cheap.  I've already tried ebay and all they have is some rip-off cheap brand and one from a 1990 that is being parted out.  Is there one from a more popular bike that will work and be less expesive??

[Chuck]

My only guess is the rectifier and I'm not exactly sure how to test it.

It sounds like you already tested it.

If you read 13 volts running voltage, then your voltage regulator is working just fine, unless the failure is intermittent or you get higher voltages at higher RPM.  Did you test it with throttle, too, or just idling?

How many amps is your fuse?  Have you installed any nonstock electrical devices (headlights, signals, etc...)?

[Chris861]

The 13 volts is w/o throttle, but I did give it a little throttle and it increased some.  The fuse is a 20 amp, and I haven't done anything to the bike.  I checked the plugs and stuff and everything seemed to be in tact, no insulation missing or anything.  I may take it for a ride again and see what happens.  I just don't want it to quit in the middle of traffic and have to replace the fuse.

[LimaXray]

I don't think a rectifier would cause a fuse to blow.  I bet you there is a wire somewhere rubbing against something and occationally makes a short.  If it's intermittant it won't be fun to find. 

Whatever you do, fight the temptation to use a higher rating fuse! 

[3imo]

read this. http://gstwins.com/gsboard/index.php?topic=25531.0

the diagram might help ya.

twer me, I'd visually check every inch of cableing on the bike, especially any areas that might be pinched (have you been working on her?)

anything pinched just cut away the sleeving and check for cuts/shorts.  and use electrical tape to replace sleeving.

good luck.

[Chris861]

Nah, I haven't done anything to the bike.  I think you all are correct though.  I was just moving it in the yard and when I turned the bars I heard a crackling sound coming from somewhere around the headlight/guage cluster

[3imo]

good spot for rubbing.  if your headlight assy has ever been dissasembled they might not have replaced the plastic tubing that circle the holes in the back of the headlight case... (did that make sense?)

anyway.  remove the headlight and you will see a sh*tload of wires.   

Have fun and good luck.   

let us know

[Chris861]

I think I found the culprit.  The guy who had the bike before me installed some progressive springs and I think the left the loom of wires that comes from the left hand grip out of the wire holder and it was sitting on the flat piece that sticks out of the front of the frame and each time the bars were turned, it would rub.  There was a hole in the wrap around the wires and one of them had the insulation rubbed off.  I wrapped it up in tape and put it where it looked like it should go.  Thanks a lot guys, maybe that fixed it. 

[3imo]

just in case. keep a fuse or two extra on the bike. for the next couple trips.

[sledge]

good spot for rubbing. if your headlight assy has ever been dissasembled they might not have replaced the plastic tubing that circle the holes in the back of the headlight case... (did that make sense?)

anyway. remove the headlight and you will see a sh*tload of wires.

Have fun and good luck.

let us know

Its called a Grommit.

[3imo]

good spot for rubbing. if your headlight assy has ever been dissasembled they might not have replaced the plastic tubing that circle the holes in the back of the headlight case... (did that make sense?)

Its called a Grommit.

is it? I order grommits here for work and they come as rubber circles. 
thats the word I wanted to use, but it is really just a plastic electric wire tubing that you can order slit down the side.

oh.. well..

I guess your right... see below


grom·met    ( P )  Pronunciation Key  (grmt) also grum·met (grm-)
n.

A reinforced eyelet, as in cloth or leather, through which a fastener may be passed.
A small metal or plastic ring used to reinforce such an eyelet.
Nautical. A loop of rope or metal used for securing the edge of a sail to its stay.

[Chris861]

Oh, I think your talking about the black plastic stuff that covers the wires. If thats what your talking about, its wire loom.  Here's a picture. 

http://www.action-electronics.com/grc/rcsl.jpg

I'm ahead of you with the fuses.  I put a whole box of them in the bag with my toolkit yesterday when I test rode it. 

[3imo]

Oh, I think your talking about the black plastic stuff that covers the wires. If thats what your talking about, its wire loom.  Here's a picture. 

http://www.action-electronics.com/grc/rcsl.jpg

I'm ahead of you with the fuses.  I put a whole box of them in the bag with my toolkit yesterday when I test rode it. 

yeah, that what I was thinking, but he's right. by definition it is a Grommet.