Hardfahrer
XS650 Enthusiast
My main fuse is blowing but not all the time. 82 xs650. Started last season when I was on a ride. I was traveling home after many hours of riding and the bike shut off. Found the main fuse to be blown. I tried replacing it and it blew again. After about 20 minutes I tried another fuse and It didn't blow and got me home (About 40 miles) Had a few rides after that and had the fuse incident maybe one more time where the bike shut off and I put in another fuse and it blew and after a while it would take the fuse and I would be able to ride home. Going on a shakedown run this season, I got the bike out of the garage and on the road, began to rev it out in first and into second and the fuse blew again. I pushed it back to the garage, replaced the fuse and it started back up. Now, and I've repeated this a few times, when I rev it up pretty high, it will blow the fuse. Not all the time but it's fairly repeatable.
I find it difficult to test for a short because it's not a dead short. I had replaced the rotor a few years back with a rotor from MikesXS. I tested the rotor and got 5.1 OHMS. Open circuit from each ring to ground. Battery voltage is 14.7V at high rev so the charging system seems normal. Did a slap test and it worked well enough. Tested the voltage at the battery and the voltage at the rotor wire and they were within .2V so no short there. Tested the stator resistance on the 3 white wires and they were consistent but I forget the exact reading at this point. I tested the 3 white stator wires at idle and am getting 10.6V to 10.7V AC at each combination of wires so that checks out. I'm getting 14.3 Megaohm resistance from the 3 white stator wires to ground which isn't an open circuit, but it's close, so that looks good.
The bike is heavily modified with different headlights and led turn signals, and most of the safety switches have been bypassed. I have an upgraded fuse box with blade type fuses. The safety relay is intact and working, The reserve lighting unit is removed. I'm running the pamco ignition with e-advancer. The stator and rectifier/regulator are stock. All of these mods were in place well before the fuse blowing started happening.
I'm kinda at a point where it's above my pay grade so I figured I'd try to take it to the forums. Are there any thoughts on what would cause this or is there a good procedure to isolate where it might be? Any help is much appreciated. I read that rotors do funny things, I imagine stators can too. I don't mind buying the new parts if it were a stator or rotor, I just don't want to throw money in the wind if I'll still be left on the side of the road fingering through my bag of extra fuses.
Bit of a side note, I bought a replacement rec/reg from xs650direct , because rectifiers go bad and I figured it might be or will be a problem. I plugged it in and my headlights didn't work. Plugged the old one back in and everything is fine. Regulator was bad out of the box it seems. I got a refund and I don't recommend the regulators from xs650direct.
Thanks again for any advice.
I find it difficult to test for a short because it's not a dead short. I had replaced the rotor a few years back with a rotor from MikesXS. I tested the rotor and got 5.1 OHMS. Open circuit from each ring to ground. Battery voltage is 14.7V at high rev so the charging system seems normal. Did a slap test and it worked well enough. Tested the voltage at the battery and the voltage at the rotor wire and they were within .2V so no short there. Tested the stator resistance on the 3 white wires and they were consistent but I forget the exact reading at this point. I tested the 3 white stator wires at idle and am getting 10.6V to 10.7V AC at each combination of wires so that checks out. I'm getting 14.3 Megaohm resistance from the 3 white stator wires to ground which isn't an open circuit, but it's close, so that looks good.
The bike is heavily modified with different headlights and led turn signals, and most of the safety switches have been bypassed. I have an upgraded fuse box with blade type fuses. The safety relay is intact and working, The reserve lighting unit is removed. I'm running the pamco ignition with e-advancer. The stator and rectifier/regulator are stock. All of these mods were in place well before the fuse blowing started happening.
I'm kinda at a point where it's above my pay grade so I figured I'd try to take it to the forums. Are there any thoughts on what would cause this or is there a good procedure to isolate where it might be? Any help is much appreciated. I read that rotors do funny things, I imagine stators can too. I don't mind buying the new parts if it were a stator or rotor, I just don't want to throw money in the wind if I'll still be left on the side of the road fingering through my bag of extra fuses.
Bit of a side note, I bought a replacement rec/reg from xs650direct , because rectifiers go bad and I figured it might be or will be a problem. I plugged it in and my headlights didn't work. Plugged the old one back in and everything is fine. Regulator was bad out of the box it seems. I got a refund and I don't recommend the regulators from xs650direct.
Thanks again for any advice.