2000 GL1500 blowing fuse IGN START CRUISE


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DenverWinger
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by DenverWinger » Tue Jan 08, 2019 7:20 am



hotrodpearl wrote:
Mon Jan 07, 2019 10:50 pm
Thanks to WingAdmin I'm now using a 12-volt bulb which has greatly saved my cache of fuses.
If you are using a little bulb I might suggest using a headlight bulb instead, fully lit it passes about 5 amps, the little bulb might continue to light even if the short is removed just from normal draw of the circuit.


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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Tue Jan 08, 2019 10:06 am

I'm using a tail light bulb............ is that to weak......?

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by Erdeniz Umman » Tue Jan 08, 2019 10:29 am

You should also take into consideration that the plastic housing of the relay could be melted and causing short between contacts.

Here is a rear view of the fuse relay box.
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ct1500
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by ct1500 » Tue Jan 08, 2019 4:41 pm

There are two red connectors above fan, you sure the right one got disconnected by confirming wire colors?

If fuse #11 15A only blows with relay 6 installed it pretty much narrows it down to Blk/Lt Grn trace wire which is main feed. With C43, 55 and 57 disconnected now undo C315 yellow connector behind left inner fairing. To cover a remote possibility C11 Green under seat at rear for BAS also undone. The red/wht to BAS is the trigger wire which is supposed to go to ground anyway and which activates relay. According to the wiring diagram those are the only branch wires off main feed that I see.

If that does not locate short undo fuse-relay box for access to that main feed wire behind and test that one wire for short with a fused jumper to CYArse confirm, I use a circuit breaker of less than fused rating and a test light installed at end of circuit for visual confirmation.

Then the fun begins following that wire forward opening the harness, wiggle testing along the way and locating short and you can tell us all exactly where those branch splices are.

As always first check machine for any previous owner added wiring, added fasteners, wire mis-routing, pinched wiring, chafing, etc. as the most likely cause.
Last edited by ct1500 on Tue Jan 08, 2019 6:35 pm, edited 5 times in total.
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by ct1500 » Tue Jan 08, 2019 5:21 pm

hotrodpearl wrote:
Mon Jan 07, 2019 10:44 pm
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?
Nope, power feed is battery, ign switch, fuse box then to fuse 11. Good thought though. :idea:
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Tue Jan 08, 2019 9:59 pm

CT1500 thanks so much for your input. I will be working on this tonight and tomorrow morning and let you know what I find. Fortunately the wiring does not appear to have been hacked or spliced into. I do have another complete 2000 wreck with a wiring harness as a back-up plan although that would be a massive job swapping the main harness. I'll post my updates.

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Tue Jan 08, 2019 10:33 pm

CT1500 ... do I leave c-43 C55 and c57 disconnected when I disconnect c315

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by MikeB » Wed Jan 09, 2019 12:36 am

hotrodpearl wrote:
Tue Jan 08, 2019 10:33 pm
CT1500 ... do I leave c-43 C55 and c57 disconnected when I disconnect c315
If there is still an indication of a short with C43, C55, and C57 disconnected then I would disconnect C315 to see if the short goes away.

If you have already have reconnected C43, C55, and C57, then leave them that way and disconnect C315 to see if the issue is resolved.

That is what I would do if I was doing the troubleshooting.
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Wed Jan 09, 2019 1:06 am

Disconnected all specified connections and still had a Short so got a magnifying glass and bright light and began following the wiring harness and found only a very small wear spot directly underneath left side cover and opened the black wrap and found melted wires....... I would have assumed the fuse would blow long before the wiring melted but apparently not so looks like a wiring harness replacement which is a brutal job but I do have one......or simply part it out which I guess I should have done to begin with

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by MikeB » Wed Jan 09, 2019 1:13 am

How many wires are you talking about? If only a few, splicing in new wiring is not necessarily a tough job. If more than 50, it would be a task but still possible. Can you post a picture of the damage?
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by Erdeniz Umman » Wed Jan 09, 2019 7:38 am

If you could add a picture of the affected area it would be very useful for future reference.

And this is the reason why I prefer removing the terminals of the battery and using a multimeter instead of a bulb method.
Also if there is a blowing fuse, we should not replace it more than three times as a safety principle.

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Wed Jan 09, 2019 10:05 am

I'll try and add a picture once I get all the damage exposed. So far I just see four wires melted but I haven't been able to get it much more of the harness cuz it goes behind the frame.

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by ct1500 » Wed Jan 09, 2019 4:44 pm

hotrodpearl wrote:
Wed Jan 09, 2019 10:05 am
I'll try and add a picture once I get all the damage exposed. So far I just see four wires melted but I haven't been able to get it much more of the harness cuz it goes behind the frame.
You found the source of the short which is good. Now you have to determine the why as to not get a repeat after repairing. The short of your feed wire occurred there because one of those other wires goes to a ground in some manner. Try to determine which wire was the originator of the heat to burn insulation through which might not have been your feed and may very well have been an overloaded ground wire. The offending wire should look more beat up being hard and brittle like showing burn before and after the point of short. Once the offending wire is found identify what circuit it is on by following it to a device and troubleshoot from there with resistance and amp draw tests.
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Wed Jan 09, 2019 10:12 pm

Still following melted wires , the main offenders at this time appear to be 2 blk/blu wires (side stand and air solenoid) that melted into a green wire with silver rings on it...….. but I've still got a ways to go...…… the melted wires I'm following now go into back of fuse relay block ……….. thanks again for all the help and advise from everyone , won't have much time for a couple days but I'll keep you all updated...…...

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by WingAdmin » Wed Jan 09, 2019 10:28 pm

It's important to know whether the melt is the cause of the short, or the symptom.

If there was obvious mechanical damage to the harness, to the point where insulation was breached between two wires, they shorted and then melted, then you know that just replacing those wires with new spliced-in wires will solve the problem.

Now if the short is actually elsewhere, it could be just that this is where the most resistance was, and where the heat was most concentrated, so that's where the wires melted together. Splicing in replacement wires in this case won't fix the problem, it will just fix the damage - until you turn it on again, and then the NEXT most vulnerable place will melt.

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Thu Jan 10, 2019 11:28 am

Thanks for your input WingAdmin , I will update you on what I find when I get the harness out because clearly it is not repairable while still in the frame.........

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by hotrodpearl » Thu Jan 24, 2019 2:16 pm

Removed the wiring harness and repaired it. the damage was limited to 2 black/light blue wires on the Left side of the bike where the side cover had rubbed through the insulation on said black/light blue wire and also a green (ground) wire where they shorted . Also found a wear spot on the black wrap under the right shelter cover so those areas are now rewrapped carefully after repair . took it out for a ride and everything is working good...….. The alternator was abit noisey so replaced it with a new aftermarket one that I had on the shelf and thought all was good as it was charging 14.1 however the next morning battery was dead so removed the NEW alternator and tested the rectifier and the diodes tested bad both direction so its being replaced under warranty so I put bearings and brushes in the oem alternator and all is good so am ready to go for a long ride to Vegas or somewhere...……….BUT it snowed 4 inches last night so I'm grounded til warmer weather...…….. A BIG THANK YOU FOR ALL THE GREAT INFO AND SUPPORT FROM EVERYONE , that kept me motivated to keep digging to solve this unusual problem . The lesson I learned is keep an eye on the wiring harness for any wear or damage and remedy it before something melts ,,,,,,,,,

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by DenverWinger » Thu Jan 24, 2019 5:57 pm

Glad to hear you got it all sorted out, and thanks for posting instead of leaving us all hanging, wondering if it got fixed :D

(Waiting for warm weather, too) Enjoy the rides!
♫ 99 Little Bugs in the Code, ♪
♪ 99 Bugs in the Code. ♫ :(
♫ Take one down, Patch it around, ♪
♫ 127 Little Bugs in the Code. ♫ ♪ :shock:

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by MikeB » Thu Jan 24, 2019 6:14 pm

That is great news. As DenverWinger pointed out, thanks for getting back to us and not keeping us hanging.
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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by Sempai » Fri Feb 01, 2019 1:03 am

So I just read through this thread, excellent group effort, great work guys, my hat’s off to the lot of you.

Reading about the melted spaghetti you found, I get the feeling this wiring malfunction has been a slow working process taking its time for a while. Seeing that kind of wiring damage, I will have expected you would have smelled the very distinct aroma put out by an electrical wire burning up, as well as the visual of the very dense white smoke emitted from wire that’s overheated enough to melt its sheathing.

I suspect the problem didn’t cause all that melting in a short amount of time. If you’ve ever actually seen such a wiring fiasco, smelled it, and watched such a wire fall from under the dash of your Triumph TR7 right across your legs as you were pulling over because you couldn’t see the windshield through the aforementioned foul smelling smoke, let alone seeing the road...let me tell you, go ahead and leave it laying on your pants, as painful as that was, grabbing it with my hand to get it off my legs was an exceptionally more painful mistake.

Lesson to be had here: if u see a dense cloud of nasally offensive smoke, and the see a string of bright white light, do not touch it with your bare fingers.
Keep the rubber side down.

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Re: 2000 GL1500 blowing fuse IGN START CRUISE

Post by WingAdmin » Fri Feb 01, 2019 9:53 am

Sempai wrote:
Fri Feb 01, 2019 1:03 am
Lesson to be had here: if u see a dense cloud of nasally offensive smoke, and the see a string of bright white light, do not touch it with your bare fingers.
:lol: I have a permanent scar in the form of a line across the fingerprints of the thumb and first two fingers of my right hand for this exact reason. At age 17, I grabbed that white hot wire to pull it off the car battery whose terminals it had fallen across. Having a wire melt while you're holding onto it sure hurts. A lot. :)



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