I keep blowing the same fuse?

[arizonawarrior]

The pushbutton start switch just sends the 12v down the line so if it were shorting across the switch it seems like it would spin the starter assuming all else is well in the circuit. And yep I think that if the black/green wire is shorting at the switch to metal ground it could cause this. Its probably best to verify all the wires first because this wasn't happening like this before the wiring re-do he just did. I think its a wire issue although who knows!

[rcoligan2]

That switch grounding out is more along the lines I was thinking Arizona! I hate to see fellow members with lasting problems like these. Just trying to throw in any kind of suggestion I could think might help.

The DarkMidKnightWarrior

[Hydro]

AZ & RC there was an issue with one of those wires being frayed and touching the blue/white wire. I repaired with solder and put a little heat shrink around the two wires.

[Hydro]

I posted this yesterday and didn't want it to get lost in the back of the room.
Any opinions on the following:

The other night after I found the torn Blue & White wire in the handlebars and repaired it I went ahead and put everything back on the bike except the head light.
The only coupler that I had unplugged was the one that is the "Right side Switch Coupler" in the headlight (I've been reading that Service Manual).
At that point I replaced the 10amp Ignition Fuse and turned the key.
The fuse did not pop.
I then plugged the coupler back together and turned the key and this time the fuse did pop.

Any thoughts?

[LeaderDuece]

I'll be honest, you're almost to the point where I would recommend getting a new harness and starting over.

[gun-runner]

08 Yamaha Road Star Warrior XV1700 Main Wire Wiring Harness | eBay

[LeaderDuece]

Does he need the main harness, or the right control (and harness) or both?

[gilly]

Originally Posted by Hydro

I posted this yesterday and didn't want it to get lost in the back of the room.
Any opinions on the following:

The other night after I found the torn Blue & White wire in the handlebars and repaired it I went ahead and put everything back on the bike except the head light.
The only coupler that I had unplugged was the one that is the "Right side Switch Coupler" in the headlight (I've been reading that Service Manual).
At that point I replaced the 10amp Ignition Fuse and turned the key.
The fuse did not pop.
I then plugged the coupler back together and turned the key and this time the fuse did pop.

Any thoughts?

If you plugged the connector together and then blew a fuse, then you have a dead short somewhere in those wires. You need to identify the color wires that go to each function and make sure they are good wires,no frays or bare marks.You also need to know what color wires are hooked the the starter switch. What color wires go to the kill switch, to the horn, and so on, then you can find out where they go. Until you do that, you are going to continue scratching your head and just guessing what goes where.

[arizonawarrior]

Ummm . . . look at my earlier reply last night, I added every wire color stock in that coupler and tagged to its fuse: I keep blowing the same fuse?

Originally Posted by Hydro

I posted this yesterday and didn't want it to get lost in the back of the room.
Any opinions on the following:

The other night after I found the torn Blue & White wire in the handlebars and repaired it I went ahead and put everything back on the bike except the head light.
The only coupler that I had unplugged was the one that is the "Right side Switch Coupler" in the headlight (I've been reading that Service Manual).
At that point I replaced the 10amp Ignition Fuse and turned the key.
The fuse did not pop.
I then plugged the coupler back together and turned the key and this time the fuse did pop.

Any thoughts?

[Hydro]

I did see that AZ and thank you. I actually printed it and used it today. I need to clarify something that's clear to me now. The six wires coming out of the right side handlebar switch (running thru the handlebars) start off with the wire colors as they should be. It's once these 6 wires exit the handlebars about 10" that a splice was made and different color wires used. Once the couplers are connected the wires go back to being the correct colors. I'm making progress and will post a separate post addressing today's finds. I'm getting close...it's right there somewhere.