Ignition circuit fuse blowing

[nigelrtaylor]

Further to my post about the engine management fuse blowing I should RTFM  The fuse that is actually blowing is the ignition & instruments fuse (number 5 in the rear fuse box). I know i'm a numpty for getting the wrong fuse last time, sorry.

I thought I had fixed the problem by replacing teh relay because teh bike was running fine. Anyway, just chekd teh bike and now power. The fuse is blowing with ignition turned off and blows immediately on putting a new one in the holder. I suspect I have a wiring loom fault

Any ideas. Maybe a look at the circuit diagram for fuse 5 would help if Coconut has access to it please.

[john348]

Check round bottom of ignition barrel.  Some people have reported the loom is very tight going to ignition switch and can wear through.

[Coconut]

John you beat me to it !

Fuse 5 of the Rear Fuse box feeds out along a White wire with Blue tracer,
and runs directly to the Ignition switch.

There have been lots of reports of wires being pulled out of the Ignition Switch connector
due to tight wiring around the headstock area,
particularly when the handlebars are turned fully to the right.

To save more fuses, I'd try some checks with a multi meter, with the battery disconnected,
and see if the fault shows up on the output side of the fuse - shorting to ground
and if there is any difference when the handlebars are turned.

I'd bet a Pint that this is your problem !

Plenty of information in this Topic : 

Ignition Wiring Failures

There are other Topics about this too, but that is the main one
and should have most of the information needed !

Cheers,

[earthman]

Best of luck with finding the wire(s) that are causing the problem, I'd certainly be interested in the details/pictures, I invested that area on my bike, the wiring loom that went to the ignition switch runs straight to the faring pocket area which doesn't actually get strained when the bars are turned. Yes, the wires that run alongside the frame on my bike do look a bit on the tight side to me when the bars are turned to the right but those ones don't go to the ignition switch!

I know that some owners have had a replacement ignition switch fitted, ended up with having two keys for their bike.

[nigelrtaylor]

Checked fuse output and it is shorted to earth. The wires around the ignition switch look OK with no obvious chaffing and don't appear tight. Whilst checking the short circuit I moved the bars and moved the wiring around the headstock. Short stayed on. Guess it's a trip to the dealership in the back of a van.

[nigelrtaylor]

The dealer found that 6 wires had burnt through in the loom where it runs under the left headlamp. There was no visible signs on the outside of the loom. This is not a place where the loom is subject to any movement.  I suspect an initial wire shorted and caused the damage to the others. Why it shorted is a mystery. Several hours of technicians time and the bike is working again. I'll post some pics of the damage when I get them from the dealer.

[earthman]

Thanks for the update, good to hear that they found the cause,.....under the headlight they say, that's intriguing.
Looking forward to the pictures.

[nigelrtaylor]

Unfortunately the photos of the wiring loom are not available. Good news is I emailed Triumph Aftersales and they are considering a good will warranty claim for the cost of the repair.