Strange foose problem

[Howley]

So I'm blowing the 7.5A fuse for the indicators, running light, instruments etc on my 94 M900.
The funny thing is it happens really irregularly. Sometimes it'll go a week then blow, and sometimes it'll only last a few seconds. Any idea what it could be? I thought it was one of my indicators, but there was nothing wrong with them.

- I tried the wiggling wires trick but of course nothing blew then.
- Once I saw the right indicator light up before it blew
- Bike was on stand. I disconnected front and rear indicators on the right and it still blew. I turned the bars straight and it didn't blow until I turned the indicators on.

[Raux]

So I'm blowing the 7.5A fuse for the indicators, running light, instruments etc on my 94 M900.
The funny thing is it happens really irregularly. Sometimes it'll go a week then blow, and sometimes it'll only last a few seconds. Any idea what it could be? I thought it was one of my indicators, but there was nothing wrong with them.

- I tried the wiggling wires trick but of course nothing blew then.
- Once I saw the right indicator light up before it blew
- Bike was on stand. I disconnected front and rear indicators on the right and it still blew. I turned the bars straight and it didn't blow until I turned the indicators on.

sounds like you got a broken wire somewhere.

[Ddan]

+1   Check the wiring under the seat.

[The Architect]

+1   Check the wiring under the seat.

Sometimes the seat will pinch the wires.  Once the jacket is worn or cut the frame will cause a short.

[Howley]

The fuse blows with the seat off.

[ducpainter]

So I'm blowing the 7.5A fuse for the indicators, running light, instruments etc on my 94 M900.
The funny thing is it happens really irregularly. Sometimes it'll go a week then blow, and sometimes it'll only last a few seconds. Any idea what it could be? I thought it was one of my indicators, but there was nothing wrong with them.

- I tried the wiggling wires trick but of course nothing blew then.
- Once I saw the right indicator light up before it blew
- Bike was on stand. I disconnected front and rear indicators on the right and it still blew. I turned the bars straight and it didn't blow until I turned the indicators on.

Does the bike quit?

My 96 did that and it turned out the kill switch wires had gotten pinched in the steering stop. It was the 7.5 amp fuse.

[Jarvicious]

Look for bend points in the wiring as well.  I was working on an ATM the other day (it's what I do) and there was a spot on a wiring harness where the safe door had opened and closed so much that the wire wasn't completely broken, but the actual metal inside the insulation had broken due to stress.  The only way I found it was because I could hear a solenoid throwing, but unfortunately I don't think you'll have that luxury.  Good luck troubleshooting

[Howley]

Does the bike quit?

My 96 did that and it turned out the kill switch wires had gotten pinched in the steering stop. It was the 7.5 amp fuse.

Nope it runs fine.

[The Architect]

Have you tried replacing the blinker relay? 

[Howley]

No, it is very old looking. Is there any way to test it?

[Howie]

I would look in the harness coming down from the switch.  If that looks good, then the switch itself.

[Howley]

The entire left switch block was replaced 2 years ago!

[Howley]

Ok I got a multimeter across the fuse terminals. Here is what happened today.
For future reference, my sidestand switch is disconnected and all the wiring from the switch is gone.

- Came out in the morning, turned it on, over 7.5A = Blown Fuse.
- Disconnected left switch block, turned it on, no blown fuse.
- Reconnected left switch block, turned it on, blown fuse.
- Put bike up on pit stand, disconnected, opened and inspected left switch block, reassembled left switch block.
- Turned bike on, with tank up, no blown fuse.
- Put tank down, no blown fuse.
- Took bike off pit stand and put it on sidestand. Blown Fuse as soon as weight went onto the side stand.
- Held bike upright, no blown fuse.
- Back on sidestand, blown fuse.
- Disconnected fuel level sensor and put bike back on sidestand, no blown fuse.
- Reconnected sensor and put bike back on sidestand, no blown fuse.
- Bike upright, shook bike around, no blown fuse.
- Bike back on stand, no blown fuse.

I'm a bit suspicious that it is the fuel level sensor and perhaps it stopped shorting when it got saturated with fuel. Anyone got any input?

[Howie]

Same circuit, so, yes the sensor may have an internal short.  Easy test is just disconnect it and go for a ride.

[Howley]

Yeah that's what I'm thinking. Any ideas why disconnecting the switch block stopped the short?