Aight - So I think I managed to track it down, and take care of it.
The flasher I got worked perfectly..picked up a $9 electronic flasher from Canadian Tire, where the local dealership wanted $25 for a universal flasher, or $45 for the Kawi OEM one. It worked perfectly with my wires, which is awesome.
The PO had 'fixed' the rear right ground on the signal light by wrapping the wire around the washer, and using electrical tape to hold it together. It was pretty lose, and full of crap. The washers themselves were brown, and after a little bit of clean-up with some sand paper, came out nice and shiny again. I soldered the wire onto the washer, to ensure a good connection.
After cleaning the ground wires for the lights, and installing the new flasher, the bike seems as good as new. The hazard and signals can be used at the same time, without that groaning I heard earlier. I think the corrosion on the flasher unit I replaced was the problem.
I can now use the turn signal, hit the hazard switch which makes the hazards work perfectly, then go back to the normal turn signal operation without any stress on the system. No blown fuses after a good half hour ride either - so I think I'm back in business!
Thanks for all the help everyone..hope someone can use this thread in the future.
Post edited by: pyxen, at: 2006/11/18 19:46