Tannermac wrote on 10/27/14 at 15:52:22:

any short will blow a fuse, if you think it's the rectumfryer, pull it, won't stop it from starting.
Quote:

the neg term is connected to frame, don't worry about short there.
chrome plate over plastic, don't think it'll conduct electricity.

There are several places most likely to short (besides all over)
Headlight is the most likely, pull the headlight, disconnect the connector, and examine the wires going thru the shell.

The rectifier is activated by the red/blue wire from the ignition switch.  If it's blown bad enough, I guess it could blow the fuse.

Just take off the seat and unplug the rectifier.  Like Verslagen said, it will run without the rectifier.  It won't charge the battery so don't go very far. If you are going to run it without the rectifier connected, pull the stator connection from it too.  It can kill it if its not already dead to have the power going in and nowhere to put it. Dunno why. Just what I've read on lots of different sites. I'm having troubles with my rectifier too. Been doing a lot of research about how it works.

The chrome is conductive but the - is connected to the frame...don't worry about that.

Um, not to question you but.... what size fuses are in your bike?

Heated grips.....  check your switch for that.... check your wiring too. It takes a lot of amps to start the heat process.
Disconnect it from your system and try again, see if that doesn't help.

Old_rider - The fuses are 20a as they are standard.  I have gone through a process of elimination and had the heated hand grips disconnected with the problem continuing.   Thanks for the suggestion though!

Serowbot - I have a bike battery charger so all is good in that sense.

Okay I have made big progress.  It took a weekend of working on the bike but I have it up and running. The only disheartening part is I am not sure what cured it.  Here's how it went down.

I stripped the wire cover and tape from every single wire.  I had disconnected all the wiring harnesses to help eliminate the possible issue area.  Nothing was curing the fuse blow.  I went through probably 20 fuses.  I did the initial easy checks grounding connections, lights and the go to wires that fire up with the key moved to "on".   Nothing was fixing it.  

When I removed the wire covers & electrical tape I found either the wires were all greasy or runny with electrical tape adhesive.  As I went through I used a dry cloth and cleaned up all the wires.  Once under the tank I noticed a harness connection with a strange colour to the one connection in the harness.  It was a kind of green colour.  Not as if it was shorting out but not like all of the other connections.  I scored the connection the best I could in case it was not connecting for some reason.

If I remember correctly the wire ran to one of the front signal lights. I looked at the left signal bulb and found that there was 3 elements in it with only 2 of them intact.  I had replacement bulbs and noticed that all of the other ones have only 2 elements.  The original bulb "worked" but I changed it out anyways.  

I recovered all of the 3 to 1 wire connections with electrical tape. and slowly put the required running harnesses together.

The bike has worked since and I am not exactly sure why.  

Have any of you heard of a fuse blowing from a bulb situation like this?  I am posting photos to go along with this.  

I was worried that some how the greasy wires were conducting electricity and shorting it out.

If in fact it was the bulb I am going to beat my head against a wall as it literally took 2 days of 9 - 5 working through the wires. I did look at the bulb initially but if I missed this simple problem I am going to be disappointed in my self!  So lie to me if you need to   (dont actually).

Hoping my misfortune and experience brings someone else help in the future.

Other side of the harness

Steve H - The original bulb bottom has only 2 contacts they are circular but the replacement bulb has 2 that are more of a oval shape.  Other then that there is no other differences.

Nope only those three things are possible fixes.

The bike is parked now and I will begin the tinkering and winterizing.