Turn signal problem and now no ignition - wtf?

If it does nearly every time, then try unplugging the R/R and while keeping RPM down to 4000, see if your fuse blows. There are tests for the R/R to see if it is defective.
Does your turn signals work now? Isn't that the 1st problem, it all started after doing some tightening inside the head lamp bucket, right? Are you sure its not a wire still grounding? Do you still have the wiring through the handle bars?
Do you have the diagram for your bike? If so you should be able to trace out the wiring/ circuit at fault.

Motor Head wrote:

If it does nearly every time, then try unplugging the R/R and while keeping RPM down to 4000, see if your fuse blows. There are tests for the R/R to see if it is defective.
Does your turn signals work now? Isn't that the 1st problem, it all started after doing some tightening inside the head lamp bucket, right? Are you sure its not a wire still grounding? Do you still have the wiring through the handle bars?
Do you have the diagram for your bike? If so you should be able to trace out the wiring/ circuit at fault.

I do still have a turn signal problem. My wiring no longer goes through the handle bars. It very well could be a wire still grounding somewhere I just can't find it for the life of me. I feel like I've checked everything short of ripping apart the entire main harness.

If your wiring is now running externally on the handlebars, check where the wires come out of the switch pods(left and right side)You may have to carefully inspect the wires and switches to find this electrical short.

The latest news:

I was finally able to track down the faulty ground connection that was preventing my left side signals from working properly. Thinking I had defeated the dragon, I went to take the bike for a test ride to make sure the 20A main fuse problem had been eliminated.

I turned the bike on, let it warm up for 2 minutes and boom. 20A fuse went AGAIN. I hadn't even put the bike into gear.

Needless to say I tucked into the fetal position and cried like a baby for a good 10 minutes.

Did the fuse blow just sitting there warming up the bike or was the handle bars turned?

I suspect insulation damage in the main bundle where it goes toward the headlight. One or several wires are touching affecting the fuse.

I'd also look inside the sprocket cover for signs of wiring damage, possible wires are moving causing your problems.

On most of the bigger 4's the alternator wires,oil pressure sensor,neutral switch and side stand switch,all run above the engine sprocket in a small channel.

MFolks wrote:

Did the fuse blow just sitting there warming up the bike or was the handle bars turned?

The bike was just sitting there. Handlebars straight

Try this:

1.Fully charge the battery.

2.Disconnect the regulator/rectifier from the alternator.

3.Start the engine with a new 20 amp fuse installed.

4.Let the engine warn up as before(if you're worried about overheating, position a fan foe cooling).

If the fuse does not blow, then it's got to be in the charging system.

If the fuse blows, further head scratching is required.