Problem with the wiring somewhere

[hawcer]

I have a problem in my 97, the problem just started today. The bike died and wouldn't start and I found the main fuse had blown. I did manage to find the green wire that I think goes to the headlamps shorting out on one of the thermostat bolts. I fixed the bare wire and moved the harness away from the bolt and put a new fuse in it. Now for the odd problem. I have constant 12v on the tan wire going to the ignition lock switch. It is not the switch, because I unplugged it and still have voltage there. I cannot turn off the bike or anything else with the key. I still can kill the bike with the on/off rocker switch, but the lights and everything else stays on.

I'm guessing I have a short to power somewhere, maybe from the shorted light circuit... melting wires together somewhere. Where would be a good place to start before I start cutting the harness apart? anything else cause this?

Thanks

[JasonRDfan]

Do you have a book? A wiring diagram would help a lot. Is the switch itself bad ? Go ahead and unplug the wires from the ignition switch and see what happens. That will help out tremendously. Do you have a volt meter? Kind of unrelated I like to turn it to ohms and check resistance in the connections.

[hawcer]

I had the ignition switch connector unplugged, it made no difference. My good multi meter is at work, so all I have here at home is a shitty little thing....but I did find the problem. The red 12v wire and the tan wire are parallel to each other at the ign. sw connector...they must have gotten hot enough before the fuse blew to melt the plastic in between them and make contact with each other. I ended up pulling the tan wire out of the connector and wiring it around the outside of the connector so the two wires cannot make contact anymore. problem solved!

[JasonRDfan]

I'm really happy you got this figured out. It really sucks when your'e having problems with your bike and the weather is so nice

[DonTZ125]

I would suggest you order a D3BS connector kit from Corsa Technic, and repair it properly - your main ignition switch isn't something to half-ass!

Tell Alex Don from TTR says 'Hi!'

[hawcer]

Half-assed is the cheap connectors used in the first place....It's three wires,two in the original connector and one wired around the outside of the connector....with it's own connection.... not the end of the world.