Main fuse opened 2 Times

[Jan_P]

Dont know if this is clever or not .Can help someone
On my 1980 -- The Stock wiring had multiple fuses
Installed a new wiring last year and was careful .Trying to get it right . Soldered a lot and used shrink wrap
Only had one fuse 20 A

After a while it happened month or so ... It Opened .. Out on the road . After pushing and trying to figure it out
I disconnected a lot. Last fuse. Go to the service station Buy a fistful of fuses . And put in a Fuse. Connected everything and drove home. Worked.

Had a PMA that is now out and stock alternator IN

I made a bypass loop .with an inline fuse holder for the Boyer Bransden. Ignition.
So this time -- Second time the main fuse opened I had the bypass there
With ignition off and inserting a fuse in the bypass I can start .
I can drive on the battery .But not using lights.

Again after driving on the Bypass To a service station .Buying another Fistful of 20 A Fuses. again
Inserting a 20 A fuse removed the bypass it worked again. Drove home

I does not seem to be the Charging Circuit since it opened on PMA and Stock Alternator.
And not The Ignition since it runs on the Bypass.
I dont think it is heat related Because the last time it was when taking it down from the Central stand Cold kick start.

I did find a fault on the downside of the flasher relay . That I changed

The controls on the handlebar left and right is new.
Cant se anything in the Wiring passing to the headlight.

Days are getting shorter Cant be without lights.. More riding when dark .. even if I can start it.
I need to put in more fuses trying to localize it. But next season.

Feel Free come with suggestions .

The bypass perhaps can be a help :Getting a bike out from a barn .And in an evaluation period .Save the Towing.
As recommended here on the forum more fuses helps find it. But as I understand it older models dont have it.
It can take some time -Cant find a fault that easy only there now and then

 

[Wingedwheel]

What were you doing when they opened? Same or different each time?

 

[Jan_P]

What were you doing when they opened? Same or different each time?

Different
First time after .. ca 40 minutes riding .at the end little faster 4 miles or so ca 100 km / h .Entering slower speed for traffic lights--Was green Straight road a couple hundred meters after lights 50 - 60 km/h. smooth asphalt road.
GOING DARK .. no splutter no misfiring just died silence .. New fuse opened directly.

Second time parked on central stand. Had time to cool down At least a bit. Coffee and Sight seeing. .
Getting back kicking on central stand standing on the right side . Its better for the knee.
Getting it down on both wheels it clanks a bit.( can have shaken something out of place ) At idle tick over Rolling it backwards a meter or so
In neutral
GOING DARK . no splutter no misfiring just died silence .. New fuse opened directly.

 

[Sky King]

Take a close look at your wiring wherever there is a rub point on metal, frame etc. I could be a bit of the insulation worn away but not touching all the time causing an intermittent short.