Blowing fuses

So I am in a little twist at the moment trying to fix up my 1982 xj550 seca. I replaced the common glass fuses it had with some fuse holders that light up when the fuses are blown. So my problem is when I rev my motorcycle high enough it blows the signal fuse so I don't have any gauges, neutral lights, horns etc... I just haven't been able to figure out what the problem is, I think it might be the regulator, but I don't know in reality.

 

first check your in box
then get a meter and check your battery voltage bring bike up to 2500 rpm
sounds like it may be a chaghing issue or you have a short, .

the best wiring diagram you will ever use
http://www.frankjohansson.com/stuff/xj550/XJ550ElectricalDiagram.html

http://www.frankjohansson.com/stuff/xj550/

this link has downloadables of the diagram

the link below explains charging system at the bottom

The Ultimate Relay, Switch, Sensor, and Diodes Guide

 

test for regulator and charging system

daja vu

 

Hey I'm in Northen Indiana , close to Gary where in Indiana are you located?

 

Hey man I am from Crawfordsville, which is 40 min south of Lafayette

 

Im from Plainfield...now living in Hobart

 

Check voltage at battery when you're idling, and see what happens as you increase rpm 'so. Voltage should stop climbing around 14.5 or so........ If it keeps going up and up and up, your regulator is bad. If it does level out, and things blow. Then you have a wiring short somewhere.

 

Thanks fiddles and XJ. I got a question fiddles. If the voltage doesn't go up at all and starts to drain the battery would that be a problem with the regulator as well or would that be the stator?

 

Still could be either. You'd have to test the stator to see if any current is being produced.......

 

the test is posted above listed as field coil and stator coil

start by inspecting your brushes and clean the copper rings they ride on
because of the way the cable runs you will have to remove the shifter cover to get a good look

 

I think your bike is just a s.l.u.t and loves blowing fuses. you should give her my number!

 

In all seriousness was everything working fine before you changed the fuse box? also how long did it take for the issue to start right after you installed it? what is the amp on the fuse?

I am curious to know if the issue is with the fuse box replacement vs the regulator.

 

I think I helped it because the guy before me got it running by getting rid of the old fuses and just putting some comps and hard wiring it. But when I put the fuse holders and fuses in it it all worked fine. Then I went for a ride and the fuse blew. Replaced it then the went again for a ride and the fuse blew again. This happened about two more times then I knew something was wrong. The amp on the fuses are 20 for the main and 10 for the others. I also have some wires sticking out cause I took off the horns and the gauge cluster is snapped in like half from a wreck.

 

tape over the exposed connectors they are live wires. unplug the cluster it has 5 lights and 2 meters in it and the fuel meter goes back into the gas tank....... unplug the fuel sensor to the tank it is left side near the tank. 3 position connectors green and black wires
which fuses are blowing or is it just the signals?
you have main, headlight,ignition and signals.

 

are you using any signals fuse items to make the fuse blow?
will fuses blow with motor off turn handle bars left and right.
check your diode block it is in the headlight bucket
set ohm meter to diode.
lt blue to yellow should read .545 runs neutral light and v meter
white to white green should read .545
green to blue white should read .545 this tests oil light through starting system (solenoid
then set to ohms
green to black red should read 8.4 ohms this runs oil light through oil switch

 

Are there any aftermarket electonic parts on the bike Eg signal lights, brake light usb charger?

Definitly tape up all exposed wires.

To touch on what hogfiddles is saying, when you give it throttle the bike generates a stronger current from the alternator that charges the battery. This current gets passed through the regulator and gets distributed. That distribution might be faulty and is creating the short.

The other two theories i have are user error or bad fuse box. Can you move the line that keeps blowing to a diff terminal on the fuse box? Also double check to make sure the connections are 100%.

If you want a quick fix with the possibility of a burnt wire or 2, use a 20 amp fuse. If that pops there is a serious short some where.

 

if your regulator diodes have failed you are puting 28 volts AC into your system turn your meter to ac and test battery voltage

 

Only the signal fuse is blowing. Tried blowing it by using all the items in the signals fuse but nothing. I just tried again and nothing blew on this short ride, might just be a wire shorting out somewhere. If I just let it idle though it will die eventually I don't have a multi meter on me at the moment but i can grab one tomorrow to do all the testing.

 

FOUND THE WIRES THAT WERE SHORTING IT OUT!!!! Some were sticking out of the gauge cluster and when I wiggled the cluster around I saw a little spark and it blew the fuse, rookie mistake. Now to figure out what the problem of it dying is and get it road ready.

 

Glad to hear you found the issue.