Help with eletrical issue.

[The Riverbug]

Finalizing bike after a billions issues, and now when trying to start with electric start no problems, but kick start it blows the main fuse. Red wire get really hot all the way to the headlamp. It was an aftermarket brand new wire harness for the bike.(xs650sf 79')
We believe coils are ok, got spark from each side. The coils are stock as is everything else. Oh yeah two years and counting on this project. ( but she's looks good!! ) Would like to finally ride this girl

 

[gggGary]

Well that sounds strange, the kick uses absolutely nothing electrical that just running doesn't.
A cut wire touching where it passes through the headlight shell is fairly common.
Unplug the headlight and see if anything changes?
I guess I'd be looking for an inadvertent mis-connect of a wire in the shell.
Easy to mix up turn signal wires.

 

[The Riverbug]

Well that sounds strange, the kick uses absolutely nothing electrical that just running doesn't.
A cut wire touching where it passes through the headlight shell is fairly common.
Unplug the headlight and see if anything changes?
I guess I'd be looking for an inadvertent mis-connect of a wire in the shell.
Easy to mix up turn signal wires.

And guess where I was tinkering around? I'm on it!

 

[nj1639]

That's a nice looking Special. Beautifull specimen!

 

[The Riverbug]

That's a nice looking Special. Beautifull specimen!

Thanks apparently the only thing I can do right is polish!

 

[The Riverbug]

Well that sounds strange, the kick uses absolutely nothing electrical that just running doesn't.
A cut wire touching where it passes through the headlight shell is fairly common.
Unplug the headlight and see if anything changes?
I guess I'd be looking for an inadvertent mis-connect of a wire in the shell.
Easy to mix up turn signal wires.

I found off of the motor a wiring harness that had a single wire in heat shrink (black) the actual color of the wire was blue, the same color as the tach and speedo light. Not sure where this would terminate? any ideas.

 

[gggGary]

neutral switch wire is "light blue"