I left it on the side of the freeway, so a quick response would be greatly appreciated...  I worked on the carbs and stuff, and replaced the plugs.  The plugs are the only thing electrical I did to it.  I was riding down the freeway, and pop!  No more fuse.  Bike dead.  Had the girlfriend bring me more fuses, and they popped after a couple seconds.  What the hell could be going wrong??

Oh, and for the couple seconds it DOES run, it runs like total crap.

When you replace the fuse, do your brake lights/headlight work properly? Maybe some wiring connectors got eroded? I don't know much about electric, but one thing's for sure....you got about 2-4 hours before they tow your bike off the hwy     Good luck

Dunno about the brake light, but the headlight works until the fuse blows.  It's strange that it JUST happened today.  I must have done something wrong when I put it back together, but I don't know what it could possibly be.  I just went back out there and put 2 new plugs in it.  It started, warmed up for a couple munites, then died again.  So it does it when it's warm.  I should also note that I was able to ride it for about 12 miles before it sis it the first time.  Now it does it as soon as it warms up.  I'm on my way to got buy some ramps and tie downs, and bring it home.  If it's still there...  This sucks!   :x

Make sure you didn't pinch any wires when you put everything back together.  Could have gotten squeezed between something and now after riding and rubbing it's shorting.

Got the bike home.  Those cheapie $70 aluminum ramps work pretty well.  Luckily, some guy with dirt bikes in the back of his truck pulled over to help.  Dunno if me and my g/f would have been able to do it.  The dude scratched my tank though.   :x   (Although the two of us woulda prolly dropped it)  Unloading was easy.  Now I gotta take the whole thing apart again and look for the short or whatever.  Not today.  I'm tired.  Beer is good.  Maybe it's time for a SV650S...

Okay, so the broken bike in the garage was driving me crazy, so I worked on it a bit.  I am more confused than ever.  I removed the tank and the side panels, and hooked up one of those coolant return tanks as my fuel tank (kicks ass, btw).  The bike started up, and seemed to run just fine.  It warmed up, and I was revving the motor, and everything's ok.  I checked the high-beams, brake lights, turn signals, and it's still running ok.  I pressed on, jiggled, moved, and tugged on every cable and group of cables that I could find, including the spark plug wires.  I mean EVERY CABLE.  I turned the bike OFF, and started it again, and repeated the process.  The fuse never popped.  So, either:

1) The tank or a side panel was pinching a cable, and I could not replicate the problem (doubt it), or
2) Something around the motor area was overheating, and wasn't with the tank off (I was going 85 MPH when it happened the first time, so it was getting plenty of air), or
3) The bike is pissed off at me for something, and trying to get back at me

I really have no flippin clue.  I was too tired to put it all back together, but I'll try that in the next few days, and see what happens.  Any help in the meantime would be greatly appreciated.

-Jason

There only one thing that comes to mind as too why your fuse was popping, to much current
HAHA Just kidding

But really a wire that is "hot" or "live" when the bike is running is some how grounding against the chassis. My guess is that it must be heat related, ie. it is burning the rubber casing off and then grounds itself to the chassis. THe other thing is that something is pinched in the wiring,.

what work have you done recently on the bike?

ohhh yeah to wire could be touching eachother also, ie a ground wire and a live wire... just an idea

I recently took the carbs apart, cleaned them, and installed new diaphragms and springs.  I also replaced the plugs (once before the incident, and once on the side of the freeway).  The only set(s) of wires that I messed with during my original work are:

- The plug wires
- The stupid clump of wires that runs on the right side of the airbox, that always make installing the airbox a real PITA.  I pulled and jiggled these wires a lot while the bike was running (tonight), and it didn't pop a fuse.

Quote from: mrblinkThe only set(s) of wires that I messed with during my original work are:

- The plug wires
- The stupid clump of wires that runs on the right side of the airbox, that always make installing the airbox a real PITA.

(Emphasis added)

Off the topic here, but while I'm thinking about it...

1) The Clymer manual has you entirely remove the airbox before pulling the carbs out.    

2) The Haynes manual tells you to remove the airbox mounting screws, but only so you can push the airbox far enough rearward that the (disconnected) carbs can clear it.

3) Long ago someone mentioned removing the airbox/carbs as a single assembly, to make the connections easier.[/list:u]I've only tried the 2nd and 3rd methods, but I must say that I prefer the Haynes sequence.  :dunno:  Leave that box alone, I say!  

A little late now, eh?     Reading the manual before you take stuff apart isn't very man-like.  I always thought the manual was there to fix stuff after you break it??  Oh, and I have a Clymer manual, so I guess I was doing it right...

I'm looking on the bright side here.  I managed to get some new ramps and tie downs out of it.  Plus, my girlfriend said I was allowed to spend a whopping $3,000 on a new bike.  I think I'm better off with my 15 year old GS.   :mrgreen:

The girlfriend tells you what you can or cant do

cant imagine what marriage would be like

Going on 10 years, so I guess we're basically married.  I will be laid off from work early next year, so she's got a point...  Aren't new bikes what severance packages are for??

Over heating motor wont pop a fuse ... Look for goats, or you might have had an intermittent ground or somehting.
Cool.
Srinath.

If I had this mysterious "goats syndrome", wouldn't the bike just quit running?  With the tank off, it ran fine last night.  I know an overheating motor won't pop a fuse, but I also know that when things get hot, they expand.  The ignition, or something else electrical could be getting hot, and the internals could be shorting out?   :dunno:   Just a thought.  I'm really stumped on this one.  You mentioned an intermittent ground?  What could cause that?  I'm not real good with troubleshooting electrical.  I could always stick a paper clip in there, and whatever starts smoking is where the problem is...  

Goats has many symptoms ... mine just didn't charge the battery, se7enty7 had fuses blow right when he turns off the bike, Goat himself had none of those I think... extra earth right in the stator is what causes someof it. No idea what yours is... might have been a old fuse...
Cool.
Srinath.

I've gone through about 6 fuses so far.  4 of them were brand new - purchased yesterday.

OK more serious... lemme see your post again...
Cool.
Srinath.

OK that additional earth connection from negative of battery to wiring harness... that will be my first suspect ... running on 1 cyl is what it does if its bad ... and might make it blow fuses as well...
Cool.
Srinath.

That's a possibility.  I'll look at it when I get home.  Is it just a wire that I have to replace?  There were times that I replaced the fuse, started it, and it ran like ass.  Kind of like running on 1 cylinder...