2000 GL1500 blowing fuse IGN START CRUISE

[hotrodpearl]

Took a 30 mile ride on a newly acquired 2000 GL1500se with 54000 miles on it And it ran flawlessly so I backed it in the shop shut it off and adjusted the handlebars as they were too high. When I try to restart it the cruise light was off and all I got was a click and found the ignition start Cruise fuse was blown. Since all I adjusted was the handlebars I moved them back into their former position thinking I may have Disturbed some wiring in there but I have since blown about 10 uses and wondered if anybody has any idea what could be a common cause for a short or malfunction . I shut off the cruise button and the Kill switch and still blow fuses. the fuse blows as soon as the switch is turned from acc to Ignition . All lights come on and signals work as does the compressor and audio ………….. any ideas would be appreciated , I have some other issues from the bike sitting a long time but can't solve them til I get the electrical problem fixed , thanks

[Erdeniz Umman]

You probably damaged the wires under the handlebar and now you have a short you need to find.

I would remove the battery terminals and use a multimeter to find the short.

[hotrodpearl]

I only moved the handle bars down an inch so didn't pinch anything but may have disturbed a bare wire in the harness or something . Everything is bone stock and I can't see where anyone has messed with the wiring but I always go back to whatever I may have disturbed...…. unless Its a separate issue . Any idea where I would go to get info on how to track it down with a multi meter.....?

[Erdeniz Umman]

Remove the battery terminals and the fuse blowing.
Then set the multimeter to buzzer mode, and connect one probe to a ground point on the bike, and the other probe into the fuse housing (find the correct terminal hearing the buzzer).
Move the cables and wires until you don't hear the buzzer, and locate the short.

[hotrodpearl]

Thanks < I'll start there

[WingAdmin]

Replace the fuse that is blowing with a 12 volt light bulb. That way you will not keep going through fuses as you search for the short, and the light bulb will not allow enough current through the circuit for any further damage to occur to the wiring.

As an extra bonus, when the light is on, it indicates the short - when the light goes out, it indicates that you have found/fixed the short. So if you start moving things around and the light bulb flickers, you know you're getting close to the problem.

[hotrodpearl]

Thanks Wingadmin , I'll try that as i'm running out of fuses

[hotrodpearl]

I hooked up a 12 volt light and it came on of course and wiggled all the wires and moved all the harnesses as much as I could with no flickering of the light whatsoever. Also the whole time the light was on one of the relays was continually buzzing or chattering, is that normal?

[MikeB]

I think you could really benefit from a Honda Service Manual.

In looking at the electrical Troubleshooting portion of the manual, it shows the routing of the power after the Fuse.
Power goes directly to the Bank Angle Sensor and to the Ignition/Cruise Relay (Relay #6).
If you remove the Relay, it isolates everything except the Bank Angle Sensor.
If the fuse blows with the relay out, then it is the Bank Angle Sensor. I've not heard of that sensor shorting out but it can happen.
Chances are, it is something on the output side of the relay but you have to start somewhere.

Take a look at the pictorial of the circuit.

[hotrodpearl]

Thanks MikeB I swapped the relay with a known good relay with the same results so now I have removed the relay and the fuse does not blow. I have a 1996 service manual and electrical troubleshooting guide, would that be the same?

[MikeB]

Thanks MikeB I swapped the relay with a known good relay with the same results so now I have removed the relay and the fuse does not blow. I have a 1996 service manual and electrical troubleshooting guide, would that be the same?

Yes, it should be the same. Maybe a few minor differences but not enough to be an issue.

[hotrodpearl]

I've done body work and some mechanical but this electrical stuff is hard to figure out...….

[MikeB]

Yes, it can be complicated.

[hotrodpearl]

Is there a conector about half way thru this maze that I could unplug to further isolate the short ?

[MikeB]

I'll have to take a look when I get back to the computer later today.

[ct1500]

I would bet the problem is in the right handlebar multi-function switch for kill switch. Disconnect C57 above the right fan or just open the switch looking for the short if you can understand electrical circuits, doing so will start to narrow down the problem. C55 and C43 will also be involved if C57 is not the culprit.

[hotrodpearl]

That c57 looks like it's a bear to get to, any tricks to get to it without pulling the fairing off?

[WingAdmin]

That c57 looks like it's a bear to get to, any tricks to get to it without pulling the fairing off?

It is a nightmare to get to. I have done it by going through the side marker light, but my knuckles were shredded afterwards. If the short is in fact there, you'll likely have to take some of the fairing apart to get to it enough to fix. Before doing that I would first do some diagnosis with a meter to try to trace exactly where the short is first (if possible).

[MikeB]

You said that you backed it into the garage to make the handlebar adjustment. Did you use reverse to back it in or did you push it back? The reverse circuit is part of the Ignition/Cruise/Start circuitry. I wonder if perhaps something happened to the switches when the reverse lever was activated. Maybe cycle the reverse lever a couple of times and see what that does for you. I know, I'm grasping at straws but it doesn't make sense that all of a sudden that 15A fuse just starts to blow for no reason after you adjusted the handlebar slightly.

[hotrodpearl]

Thanks for your input CT1500 but I was able to unplug those three Junctions and it still has a short but at least we've eliminated those three. Could it be right in the ignition switch seeing's as soon as it goes from accessory to ignition the fuse blows?

[hotrodpearl]

Thanks for your help MikeB and I did use reverse to back it approximately 50 feet into the center of the shop from outside. I put it on the center stand and then shut it off. I restarted it and cycled it through all five gears because I was hearing a bit of a rumble between 2200 RPM and higher and was suspecting an alternator bearing. It was after that that it wouldn't start and I found the blown fuse. I did think of reverse because I know it's in that circuit and did cycle the reverse lever three times with just more blown fuses . Thanks to WingAdmin I'm now using a 12-volt bulb which has greatly saved my cache of fuses.

[MikeB]

If you have disconnected C43, C55 and C57 and there is still a short, there is not many other places to look.

From point S180, It looks like C315 is the next likely suspect. It goes to the Pulse Secondary Air Injection (PAIR) Solenoid and then to the ECM.
Also, C11 and C32 which goes to the bank angle sensor after the #6 relay.

You have already pulled the relay and found that the short was gone with the replay removed. That eliminated one side of the Bank Angle Sensor. The other side of it which is connected to C11 and C32 are supposed to be at ground potential so that should not be causing the short. A ground on that side of the relay coil would just allow the relay to energize, which is what it is supposed to do.

If we knew where S180 is, you could troubleshoot from there. I do not know where S180 is.

[MikeB]

C315 is a two sire connector that goes to the Pulse Secondary Air Injection (PAIR) Solenoid. If that wire pair got shorted together, it could be the source of your problem.

[hotrodpearl]

Thanks Everybody , I'll work more on it tomorrow evening , I appreciate everyones help...….

[hotrodpearl]

WingAdmin I was able to get at C57 thru the marker light hole and I had a 6 inch hook tool that I slipped in behind the backside of the plug and was able to hold it in place when I pushed it back together with only minimal bloodshed......