Tracing an electrical short

I am blowing fuses on my turn signal circuit. I am also very weak when it comes to electrical problems. Since circuits are sequential my logic is to start at the brake switches and move toward the headlight rats nest. This is the path from the fuse box to the ignition and turn switches. Am I correct in assuming that the trun singal canceler and relay can be ignored as well as the turn signal lights since the fuse blows without using the signals and that they would not cause a short since they would not recieve power until the turn signal button is pushed?

 

Sounds like the wire is shorted befor the switch or in the switch. Check where the switch mounts. when the screws are tightened down the wires may become pinched against the handle bars. This is a common area for the wires to be pinched off. Then move on to the rats nest.

 

Electrical problems are never easy to find. I would start with the common items that can fail(switches and bulb sockets) and look for burnt spots, bare wires, frayed wires at switchs and sockets. Take a close look at the wiring harness as it passes through frame supports and look for discolored wires. Everewhere the wires touch and rub metal parts is a possible shorting point.
Common short points:
head light bucket
frame suports
turn signals and switches
The wiring harness between the frame and headlight(this is the place where the most stress is on the wires from the handle bar turning).

A good way to start the process is to put your bike on the center stand and remove the seat and tank. Replace the fuse and turn the ignition "on". Start moving the wires on the bike in the spots you suspect there is a short. Go through the entire bike and move and wiggle all the wires, trun the handlebars back and fourth several times, turn all the switches on and off. Keep doing this until you find the spot that makes the fuse blow.

 

I should have stated that the short is intermittent. I have to ride about 6 miles before it blows. It blows riding straight and level. I had previously removed the gauge cluster to replace the 194 wedge bulbs with LED blubs. So I think the rats nest is where I will end up. I also had one of the mounting blots to break off in the headlight bracket on the tach side. Could this be a ground problem with that bolt?

 

Intermittent shorts are the worse. You can still get the bike on the stand and try moving wires. It's the best way I have found to locate them.
Yes broken or loose ground wires can cause fuses to blow. Look carefully at the gauge cluster to be sure there are no pinched wires.

 

the turn signal canceler has a ground in it so don't count it out yet
if it's unplugged do the signals work manually ? i don't know maybe give it a try
that broken bolt most likely landed on plastic ? so it would need to touch a ground and turn signal connection each time
i see lots of test rides in your future

 

If you have a stock fuse panel ...

Cut it out and install a new fuse panel.
The vast majority of electrical problems on the 80's XJ-Series Bike's are related to:

Fuse Panel disintegration.
Corroded contacts
Low charging output due to Alternator Brushes below specs.

 

Fuse box was the first thing I replaced. I had a homemade one in there and suspected it was the problem. I now have a 6 circuit Wirewerks box in there. Sure does look good! I checked the turn signal switch on the handlebars and found nothing. No pinched wire or arcing evidence. Rear brake switch looked good so I am concentrating on the rats nest now.

 

Well I am happy to report I had some progress today. My regulator checked out ok and while checking circuit relays my buddy Milt came by and noticed a bare wire. This could have been blown up toward the frame by the wind and grounded on the frame. So I peeled back some old electrical tape to reveal a wire splice. One I know I didn't do. I don't use electrical tape, I use heat shrink. Plus I had no reason to splice in these wires. So I respliced and sealed with heat shrink and now it is much neater and clear of grounding. Actually there were 3 splices that I fixed. I will put the bike back together tomorrow and see how it goes. May not be the problem but it was the only thing I found that looked like a possible cause.

 

Here is to hoping! Wise choice that heat shrink stuff. I'm particularly taken with the environmental shrink. Water-proof, period.

 

Thanks for the hope but it is still blowing the fuse. I guess the ride after ride each time disconnecting a part until finding the culrit will be my fate. Oh well, I'll try wait until tomorrow.

 

Where would a canadian like me pick up a wirewerks fuse box? I'd rather not have to order from the states, and I checked at Napa and Lordco and neither carry wirewerks. Me thinks it would be a good preventative measure to get a new one, and the wirewerks looks like a good fit.

Thanks

 

You are right in trying to get the fuse box replaced!

I tried to find one in my local area and gave up. If I remember correctly I did find a supplier that could order it but the price was way too high.

You could try some of the boat suppliers down in your area to see if they have something similar.

Nothing wrong with ordering from the states and our dollar is worth a lot these days !!!

 

THanks for the tips Nick. I've got nothing in principle against ordering from the states. It's just that when ordering new stuff you have to pay duty...and of course there's shipping. Plus, I hate waiting. Me want now

I bought some new posts for my fuse box last year, but when I saw that wirewerks box, it looked pretty slick.

 

What if your Evil Twin living in the States sends you a Birthday Present well in advance of your Birthday?


And you send your Evil Twin a Money Order to get himself a Birthday Present because you never know how to shop for him???

 

If you ship via the postal system you rarely get charged any duty.
If on the other hand you get something via UPS you get BURNT on shipping and duties!

 

Rick, hmmm, you seem to be implying something...Is it that my twin brother is evil....

Seems like a lot of work for a $10 part, but if suddenly I find my long lost twin, then let's do it.

Nick, if what you say is the case, then perhaps I can just order it up.



THanks, guys.

 

Heh heh heh, muahh, muahh (continue with meniacal cackling). And just who wants to be the Evil Twin? Of course my brother has the t-shirt but I always introduced myself as such. I think we have more than a few members who would offer up their services, myself included.

 

Thanks Robert, that's awful nice. Let me look into the snail mail angle first. But you might find a humble request in your inbox one of these days.

Cheers.

 

I found it!!! It was the rear brake switch. I unplugged it yesterday and haven't blown a fuse yet. Anybody got a switch they want to sell? I am so happy! I have my turn signals, tach and brake lights back now. Thanks for the help dudes! This is my weakest area on the XJ's and I have really learned a lot from this experience. Unfortunately I bought a wiring harness I don't need so if anyone needs it let me know.

 

New or used? If it is new, I'm interested.

 

Sorry it is used Robert. Came off an '83 Midnight Maxim.

 

where do you get your fuses? I saw some on bike bandit.com but is there anywhere they are cheaper? are they common or easy to find?

 

Fuses ought to be the most common part there is to find for any bike or car.

Auto Parts Stores, Hdwe Stores, 7-11, Convenience Mom & Pop Stores.

There's fuses everywhere!