I have looked through the forum and studied a couple of similar posts but still haven't been able to solve  my problem.

I am on my second day searching for a short that keeps blowing my relay fuse. I have narrowed it down to the headlight housing. Here's what I have found so far.

Bike shorts and blows the top fuse when starting.

I remove the headlight housing and let it hang down. Bike starts fine.

I screw the headlight housing in and bike shorts and blows fuse when I try and start it. It seems to short primarily when the bike is on kickstand and handlebars are toward kickstand.

I cut away most of the plastic wire wraps in and around the headlight looking for a worn or frayed wire and pinch points but everything is in perfect shape. I also don't see any pinch points around the gas tank or anywhere else.

Today I wrapped electical tape around the plastic wraps I had cut away and around as much of the wiring as I could and it seems to start fine.

I am concerned about not being able to find the problem and am increasing worried about the reliability of the bike in general. Not long ago I had the reg/rect die which cost me a battery and the new reg/rect. Not to mention having to leave the dead bike in a bad area of town.

Has anyone had similar problems? Any help would be appreciated as I am at my wits end!

Thanks

Don't forget that the turnsignal wires are in there too.

Does it blow the fuse immediately when the key is turned to On, or does it do it when you push the starter button?

zubaz wrote on 12/31/69 at 16:00:10:

Intermittent is always the head scratcher...

Well, that narrows it down to some specific wires then doesn't it?  The ones coming from the right hand control side for the starter button and kill switch...only as long as you are sure it is behind the headlight.  If not there, then you need to go to the decomp module and the starter relay.

Got a schematic?

The decomp module isn't gonna be it.  I'll bet on it.  
I just brought it up because it's involved and controls the starter relay.  The starter relay works most of the time, right?

But do make sure that you don't have any starter related wires shorting.  Follow it back from the switch to the module, the relay, and the starter if you need to.  You'll find it if you go by the colors.

Might be good to disconnect the starter at the relay while you test.  Save on fuses and it'll still click anyway.

Greg,

I just got your cd in the mail also. It is very well done and worth it.

Thanks,

zubaz wrote on 12/31/69 at 16:00:10:

Thank you.  Thank you.  Glad to hear.

You will find photos of the inside of the right hand controls, the decomp module, and the starter relay in the electrical folder.  Use those with your manual and I hope that you find the wiring problem....