Electrical nightmare starting!!

[Troll]

every fuse has 2 sides. load and supply. The fuse protects the load side, the main fuse protects the supply side

[Nanook]

I'm certainly not the first one to run a trailer with a drifter 800. The only additional load is the light bar, and I been running it for two years without any problem. I think that maybe the two problem are two separate thing that happen together but not necessarly related. Maybe the system was temporairly overload when the main fuse blew. But I dont see why it would only melt the front accesory wire? When the wire melted the fuse box was hanging on the side of the frame when I started the bike to test the main fuse, so it might have shorted there. But if the short happened there would'nt the wire be only melted between the fuse box and the short? The other thing that puzzles me is tha the 10a fuse did'nt blew, after the melt the fuse was still fine? Any explanation why? It should have blown and left the wire Ok? How come it did'nt?

[CDNRatMan]

Robert you might want to look at this item.

https://www.youtube.com/watch?v=Q8aKE5H9k-A

[chief]

You added way more electrical load to the bike than it was designed to handle. Troll's recommendations are right on.

[Troll]

You have the harness out, right now. Unwrap it and trace any wires/separate any that melted together. Insulate them and/or replace them with new wire, if the insulation is breached. Sounds like something shorted to ground on the supply side to your accessories. Don't over load the individual stock wiring circuits. You would be much better off installing an aux. fuse box to handle extra loads. Once you have repaired the harness, and it's reinstalled, add things one at a time, making sure there are no shorts to ground

[CDNRatMan]

not sure if this helps but found this and now I am wondering if I am reading it correctly.

Wait for Troll to explain all this electrical stuff and educate us ....

[Nanook]

Everything went fine with all the lighting, the trailer and the iphone, for about two weeks the problem just appeared when i plugged the sena for charging....maximum 5-10 watts draw. Then the rest is a cascading effect from that event!

[49Reo]

...sounds like the mighty Troll needs to weigh in here. This is right up his alley. Just sayin'......

[CDNRatMan]

 ok electrical is not my strong suit, but seems you have a lot of draw on the system, You will have to find out what the output is on the bike then see what you can change to make it a lighter load. I know GB had issues with his 800 when he swapped out his spot lights to 55 watts, and I put LED lights in my spots, lot less draw on the system. The rear signal/ marker lights are drawing more then normal I'll bet. Makes me wonder if the bike is made to haul a trailer.

[Nanook]

Ok, not sure were to start now. A week ago I did add a trailer harness for my bike, ran with it for a week without problem. I also have an iPhone jack which plug in the battery tender plug. And in the side compartment I have a cigar plug with USB for charging device directly wired on the battery with a fuse. For lighting I have a special set up on front which is working flawlessly, main headlight with two 30 watts amber driving light wired on the front accessory in the headlight which act also as turn signals with a relay. At the back I've put the front turn signals with red lens and they're use as position and turn signals.
Ok now the recent nightmare. Yesterday I was ready for a camping trip. Plug the trailer, the iPhone, and one sena communication device on the USB in the side compartment. 5 km down the road the engine dies, and no electrical. After investigation I realized that the main 30 amp fuse is blown. I said to myself that I've reach the limit of my generator. Unplug the USB charger and the iPhone, change the fuse and went on a 300 km trip without any problem. On the way back I realized that my front turn signal connected on the front accessory are not working. Back home I checked the fuse and the accessory front 10 amp was blown. I put a new one in and the main 30 amp blow up. I replace the 30, check the accessory 10 and everything seem fine. Before putting the fuse box back in I decide to start the engine to see if everything was fine. A big smoke came from near the fuse box, so I stopped everything. The wire to the front accessory blew open and melted. After further investigation I realized that the wire blew on all it's length splitting the wrapping on the main loom from the fuse box to the headlight. It may have been problem with the front accessory or a short between the fuse box or the main fuse box and the frame, not sure yet. Investigation is going on, the loom is off the frame, probably need to be replace in case some other wire melted in the process or at least replace. not sure were to start for finding the cause of all this, it would be quite annoying to replace the loom just to have it melted again.....any clues from the audience?