A sudden influx of electrons.  

Connect the Positive cable to the battery FIRST, then connect the Negative cable. You might just be inadvertently touching the frame with your screwdriver when tightening the screw on the positive terminal. It's pretty close quarters if you're working in a stock battery box with an OEM sized battery.

psutton wrote on 07/29/15 at 15:03:01:

Any idea what would be causing this?

Too much in rush current. Make sure that the electrical system is off (key out) and that there aren't any dead shorts.

I have removed/installed/removed/installed (ad nauseum) my battery about a dozen times in the last 3 weeks. There are several places that the battery can short to the frame if it is not hooked up carefully.

If you had a perfectly functioning bike (except for the weak battery) before the problem, then it is likely that you are causing it.

Proper fuse is a 7 amp IIRC. remove the fuse first.

Check that the battery box bolts (on the bottom) are tight and that the box doesnt move around.

If you have a usable replacement battery, the terminals should face the rear of the bike and the positive should be on the RIGHT side.

Install battery all the way, making sure it is as far to the left as it can go. Do this with the battery terminal screws OFF of the battery.

There are 2 wires on the positive side. A large wire with the battery connector terminal on it, and a ring-lug for the fuse block. I put the ring lug UNDER the larger battery connector terminal, but that is just my preference. Regardless, install these 2 positive wires using a long phillips head that has electrical tape wrapped around the entire length of the screwdriver shank. When you have gotten it as tight as you can with the screwdriver, finish off with a 10mm open end wrench. Good and snug, but dont over tighten it.

Pull the rubber boot down over the terminal that you just attached. Make sure that the boot fully covers the exposed metal of the connector terminal and that nothing is touching the metal battery case.
Do NOT install the battery cover/tool bag holder yet.

Now install the negative terminal with that same insulated screwdriver. There is only on wire on the negative side. Again, make sure the wire isnt cut, bunched up, or pinched.

With keys OUT, install the fuse. If it blows immediately then you have a wire pinched somewhere. If it doesnt blow, turn the ignition to the ON position for 10 seconds, then off again. Check fuse. If it's still OK, try starting the bike.

If you have a running motorcycle at this point, then it may be that you pinched a wire when you installed the internal battery cover/tool bag holder.

eplace fuse with a 12v light.
when you connect battery, the light won't blow.
and when you fix the condition, the light will be off.


You GO,  Boy!!!

The fuse blows without the keys even in the ignition. I'll go buy a light bulb tomorrow and report back with my findings. I appreciate all of your help on this.

A  blown fuse and a dremel and soldering iron.., Heck, alligator clips,,