Ok. After many long hours and almost 25 fuses. Well actually I had 6 fuses left. I think I have triumphed over the shorting demon problem.
Well as you have read in previous post, I was having problems with blowing fuses and needless to say I was getting very very mad. I was ready to give up and take it to the dealer and let them deal with it. so with that said, here is my story.
All day at work I pondered the delima and almost blew a fuse in my brain. I got home for lunch and just kept looking at different threads and such but nothing. So I get off work. Head over to the auto parts store and grab and box of 25 15 amp fuses. I got home. Sat down and had a really nice Microwave Meal, grab the ol HD Service Manual and started looking at the wire digrams in the back. I am no electrical person, so it was pretty much getting nowhere, but I charged on.
After eating my meal and just about had enough of the service manual I put on my shorts and Tail of the Dragon T-Shirt and headed out to the garage. Man I had that bike torn down to it skivvies. Bulbs pulled and everything just hanging everywhere. Wife was walking the dog thought I was nuts. After a while I did to. Anyway. Here I am....almost 5 hours into this thing, and down to 6 fuses.
I put the 7th fuses in, and bang the it did not blow. Man my heart was pumping 900 beats a min. I thought I had it. So at this point, I doing the PEE PEE Dance and started putting everthing back together. Just before I put the outer fairing on, I wanted to give it another shot. Turned on the switch and everything was ok. Man I am singing the song Holy Holy Holy.
So here I got put on the outer fairing and turned on the switch and bang. Blew the fuse. It was as if someone had chopped of my legs. I just wanted to drop to my knees. So I started thinking it was when I put the fairing on. So off the fairing came and started checking and blowing fuses again. So here I go. Start taking everything apart again and by this time I was just going to put it back together and pack it up.
I was so mad, I just turned on the switch and started graping wires in the fairing. I am poking and proding and poking and I just gave up. I grabbed a hand full of wire and moved and bang. I saw sparks shoot out and hard a cracking noise. I said WOW what the heck was that.
So I started looking at this set of wires and low and behold this is what I found.
As you can see in all three photo how the cables are ran. These cables were butted right up againt the metal bracket. Who knows how long it had been that way, but surly long enough to rub down to the wire. Then i got to thinking. I had the dealer do a 50k service and they also removed the front forks and serviced them. But I don't know if they had to remove the inner fairing or not, and I know that they replace the steering head bearings also.
So then only thing i could do was put some die electric grease on black electrical tape around the wounds, and here was my SOLUTION TO THIS PROBLEM.
I try not to throw anything away, and just happen to have this small black hose in my roll around. Grab the sissiors and some plastic ties and bang.
Hopefully problem solved. I put the outer fairing back on, and check everything out, works like a dream..................Sorry it is getting late, and I just had to pinch myself and head outside to the garage to make sure all this I was typing was not a dream. But it works. I am debating on weather or not to talk to the dealer about this for just let it ride. I got photos so I think I will take them with me.
Thank you guys for all you advice, and all the help. I just wanted to post this up, and sort a give everyone a heads up that next time you have your outer fairing off? Look around in there and make sure that nothing is rubbing around. Just put a rubber hose over those edges. It may save you a bunch of heartache down the road.
Again Thanks