30A Ignition fusing popping on bandit

[mudcow007]

Weird issue on my Bandit

it has a 30A fuse behind the right hand fairing where the lead comes off the battery an is covered with a clear plastic guard

riding along a few weeks ago, the bike just died in the middle of the road, checked fuses (in the lil box under the seat) all good, lights would work so battery was working etc...anyways traced it down to the 30A fuse in the fairing

replaced the fuse an all was well in my world - but

if i ride the bike, then turn it off - it pops the fuse again!?

just opened the kill switch an all looks good

any ideas....pretty please?

[Copycat73]

only once have I seen this ... GSX400f... was the alternator .. one of the phases had burnt out ... volt meter reading & continuity test time...

it fried the reg/rectifier too...
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[mudcow007]

pants.....although it does give me an excuse to try out my new "Fluke" tester

looking for around 14v at the battery when at 5k ish?

[Copycat73]

yeah .. but make sure your lights are on doing the second test reading .. cos under load it can supply only 66% of normal current..
a continuity test of wires from the alternator to earth is the real test..
____________________
Whatever I post I have no citation and no intention of providing one..
caveat emptor

[mudcow007]

didnt get a chance to check voltages etc - will do that today but had a quick look at wiring an from what i have seen nothing is rubbed etc...thats not to say it isnt hiding in the loom somewhere

rode it to work this morning (with a pocket full of fuses), got to work no problemo whats so ever.

hit kill switch as im parking up, switch back to run, turn the key and its dead again?!

how did kill switches work?

[Copycat73]

they run a live spur to earth ... well the ones I`ve seen ... will be on your wiring diagram ...

when mine went there was no damage to the wiring harness what so ever ... even the battery was intact .... and the thing with the kill switch / key ignition is spot on the same ....
what I was told then, was to ride with my lights on to stop it happening again ...
____________________
Whatever I post I have no citation and no intention of providing one..
caveat emptor

[mudcow007]

well, after an uneventful commute this morning....the bike died about 20ft outside of work

replaced fuse just to get home an it popped 10ft later

replaced again an stuck headlight on (as per copycat's suggestion) an it popped again - so i think i now have killed it

left it in work - fingers crossed its still there tomorrow

[mudcow007]

still havent been able to get a voltmeter to the bike yet but,

turned the bike on (with a new fuse in) after a few mins the fuse popped with the bike running.

with the kill switch OFF i pulled the 30A fuse out the ignition circuit an as i did i got a few sparks

with the ignition off that circuit shoudl be dead shoudlnt it!?

[Vincent]

Does sound weird....is the battery + lead shorting out somewhere? Or ignition switch shorting out?

No alarm?
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[mudcow007]

think ive sussed it

just took the fairings off the arse end - wires look ok

so took the tank off, from what i can see the main loom goes under the tank on the left side an what do i spot with the tank off...

https://i25.photobucket.com/albums/c81/mudcow007/Mobile%20Uploads/20150812_160019_zpsofkazcr2.jpg

a thickish (well thicker than the other wires) red wire has been chaffed by the tank

ive never been so happy to find something damaged before

so any thoughts on how to repair it?

[Vincent]

Probably the live for the ignition switch. If you can, solder it. Then shrink wrap. If not, I'd splice a small piece of wire in and, if possible, test continuity on any wire that may be damaged too. Obviously, try and work out why it's chaffing
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