key switch fuse popping

[FireboltRider31]

heres what im having. 2009 firebolt head light wires got crossed and popped head light fuse. replaced that went for a test ride and popped another fuse. thought it was the light fuse again but instead was KEY SWITCH fuse. took bad one out put new one in and insta pop... btw key was in off position when popped. so what to do now... is it possible i killed ign switch or something when crossed wires first time and popped head light fuse? PLEASE HELP

 

[Sirius815]

You need to check the wire harness for shorts. Most likely it's right around the triple tree. There seem to be numerous people that have had wire problems in that area.

 

[FireboltRider31]

lol k let me clear that up. i just finished rewiring the entire bike a week ago and checked all wires then. i know its not a wiring issue. the issue is I set up a front bracket for a single headlight and just left the other headlight wires dangling becuz i was awaiting my bracket for both headlights and the ground and power wire for the dangler touched and popped my headlight fuse. so wires are good just dont know where to go from here. had thought possibly the ign relay but dont know how to check it. i have multi meter just not sure of procedure to check relay. can anyone help with this?

PS have put new bracket on so dangler wont be an issue.

 

[jimijeans]

If your poping a fuse instantly, More than likely depending on what wire touched grounded and when a fuse pops that quickly it's grounded out.So somewhere a wire is touching metal OR another wire. Unless it is not wired correctly. You will need to remove the headlight and check for a possible melted wire to a another. Also might want to get another relay to replace 8 bucks or so at the Dealer or American Sportbike .com/ That said you need to (Mark) the old relay and with a test light check the wires feeding it.Now you have a grounded wire and it is a power wire at that,OR the relay is bad. It's a small area so it will take a little time to find it. I would if it was here in the shop would start right at the headlight that was modded and work back from there towards the steering.Then to the Relay box [left side]on Stock Bike. There are 4 of them. There are no shortcuts to electrical so make sure the power wire to the headlight going to the keyswitch on isn't melted to the fuse box wire. BTW-check the high beam wiring as well.I realize you just did some mods so take your time and you will find it. Even when all new & rewired it doesn't mean the wires are now ok,or you would not have this problem.This type of electrical problem is more about Visually checking the wiring first then going from there. Remember if your keyswitch is off and you popped a fuse, then power was still (on) some where and that tells me a possible wrong wiring or grounding situation. There should be no power when the key switch is off in this area. If key is [off] and it blows a fuse then you have ign., power wire grounding out to either metal, or another wire. Wiring is a tricky deal and all we can do is give you ways to solve the problem.Not all of them [suggested] will pertain to your problem but these tried practices with some patience you will get you in the right area to the problem.Hope it is an easy fix.~Jimi

 

[FireboltRider31]

thank you and i apologize for sounding like an ass. I read my 2nd post and i sounded a bit like an ass so yeah. anyways I put my foot in my mouth becuz i went and disconnected my wiring from left side of handlebars ( horn hibeams blinkers switch housing harness) put in a new fuse and bike started right up with no problems so obviously i spoke to soon and assumed my wiring was good. well im an arrogant prick aren't I lol jk. soo now im gonna start looking thru that harness and where it connects. ty for your time

 

[Sirius815]

At least you narrowed it down the left side