Signal Fuse

I have a 1980 XJ650 and the signal fuse keeps blowing. This prevents me from having a brake signal, horn and turn signals. I'm having difficulty tracking down why it keeps blowing even with all of the signals connected. I currently have the horn wires jumped since I do not currently have a horn. There's also a red and blue lead that don't seem to go to anything in headlamp assembly. they both have female ends of a bullet connector.

 

Soomewhere you have a short..
When does the fuse blow, right signal, left, or brake light?
That will help you find which circuit.
Likley its where a signal wire passes thru the mount, shorting to the frame.
Bad ground anywhere can cause similar issues.
Hope this helps

 

It shorts when I turn the key.

 

what do you mean by " I currently have the horn wires jumped since I do not currently have a horn."
the pink wires to the horn are hot live voltage. when you press the horn button you are making a connection to ground.

unplug the blinker canceling unit Flasher canceller: under the rear of gas tank, behind ignition coils. its about 3 inches long

unplug your directionals check wire colors
unplug the brake lights check wire colors
reconnect 1 system at a time untill fuse blows


signal fuse controls
blinkers and pilot light
brake lights
Horn
Neutral pilot light and switch

in diagram R/W wire comes from key switch



'

 

The brown and pink leads that connect to the horn are currently jumped. I did have it open before. Fuse still blew.

 

Undo those thats a dead short

 

It still shorts without them jumped. That is it's current state, open.

 

the first thing to do is unhook all the components that are on the signal fuse

blinkers in the head light bucket and at rear of bike disconnect and label the connections
disconnect the flasher unit
unplug the blinker canceling unit
brake lights you can unplug front switch in bucket and the connector near foot pedelor unplug at rear of bike
Horn unjump the wires
if fuse still blows after disconnecting every thing you want to look for pinched wires.
if not start reconnecting things 1 at a time

start with flasher if fuse blows with flasher installed you may have a lose wire in the control

 

If the neutral switch is on this circuit I wouldn't be suprised if that is where my problem is. The light is very dim ( only visible at night ) and only on when bike ISN'T in neutral. Bad switch blowing fuse?

 

yes the neutral light is on that fuse

check out your diode block

 

Diode block replaced with brand new one.
Wires cleaned up front and rear.
Fuse still pops.
When I get off work I'm going to see if my neutral pilot still lights.

 

check the connections for the signals the ground is not isolated it connects directly the mounting stay (metal rod
holding the light fixture).
one hot lead is green the other hot lead is dark brown
the black grounds are a heaveier wire . could also be the hot leads are chafed where they go through the shaft

 

take the left control off of the handle bars
look inside under the switch mechinism is 3 wires see if the brown/white wire is still soldered to the little brown pcboard it is hot and could have come free and is grounding to the control body through the bars. there is also a dark brown and green wire on the board.

you could just disconnect the 2 connecters from main harness to isolate the control then see if fuse still blows. if it does the control is not the problem

 

That is a normal condition if the signal fuse is blown or missing and not supplying 12V to the signal circuit. The neutral light is being dimly illuminated by the 12V ignition from the starter cutoff relay to the neutral bulb and attempting to supply power to the signal circuit through the neutral bulb.

This is good advice

 

have you unpluged the self canceler yet to eliminate it as problem?

 

It was this unit.
I thought I had checked it when I unplugged the other relays on the circuit, but here we are! Ok. So new canceling unit and should be all good. Few other things to clean up now, but most importantly, I have a functioning brake light.