blowing fuses with starter trouble

Hi everyone,

So I searched for this, but none of the other posts seems to have the same combination of issues I'm experiencing.

So here's the history.

When I got the bike (1983 KZ550 LTD) the starter button didn't do anything. The right switch assembly was corroded to hell and was practically falling apart. However, I was able to start the bike by bypassing the starter solenoid with a screwdriver. I replaced the switch assembly and now the starter button works, but it doesn't start the bike. it just blows the main fuse. I though it might have been the starter solenoid since I wasn't getting a "click" when I hit the start button and the fact that the fuse box was getting juice led me to believe the button was in proper working order. I replaced the starter solenoid and I'm still having the same issue. It doesn't "click" or anything, just blows the fuse.

What should I troubleshoot here? All help is appreciated!

Thanks,

gintree

pinched/shorted wire in bars?

I've given the wiring a quick go though and didn't find any obvious problems. I'm gonna get a multimeter in the next couple days and start trying to pinpoint the issue.

What is the closed circuit of components that would be shorting out? I guess I want to know everything I need to check!

Thanks for the help.

Take the right switch pod on the handlebar apart and look for a pinched/shorted wire.

The starter switch will easy to find, just trace back and see if it is pinched or shorted to ground. Vibration and age of the wire can cause this kind of problem in almost any bike.

Hey yall,

Thanks for the advice. It took me forever to get a chance, but I finally got a multimeter and tested the wiring and fixed a couple issues. I pulled the switch assembly (which is a new aftermarket unit for an XS) and checked all connections and wires. They looked good, so I gave it a try. The bike starts right up!

So I'm thinking I got it all figured out. But, once I put the switch assembly back on the bars it starts blowing fuses again. So it looks like the construction of this switch assembly grounds the starter button to the switch housing (which is metal) and when you mount it on the bars it shorts out. So I dug out the old throttle/switch assembly (which I thought was toast) and hooked it back up and mounted it. It works!

So... I'm happy about fixing the issue, but I'm confused about the xs switch housing. Let's say I had an XS and was using that switch housing, wouldn't it short the xs starter circuit as well? Is there some fundamental difference in the way an XS is wired compared to a KZ?

any experts know?

thanks

I had the same problem. I just wrapped the handle bar with electrical tape where the switch mounted to the handle bar and problem solved.

I was thinking about doing that, but I was worried that the electrical tape would eventually wear through and leave me stranded! How long have you been running it like that?