Blown fuse problem, HELP !!!

I need to pick your collective brains once again. Yesterday a fuse went on my 99' and i thought no big deal. changed it and poof new one goes. checked all the indicator bulbs (indicator fuse thats blown) and all intact and working. new fuse again then.
This one managed till this morning and poof, dead. again put a new one in and it works. tried turning bars to see if any wires are chaifing but nothngs shown. The bikes now working but everytime the indicators go it trips the speedo, rev counter, odometer but the lights still work (different fuse).
I've checked the wiring diagrams, Checked for loose/chaifed wires, any water in cable housings. NOTHING. It seems to be doing it as and when it wants to with no real pattern to it.
Anybody had a similar thing happen to them??? What was the problem ??? how was it remedied ???

Have you had a look at the rear brake switch?

Somehow mine got completely burnt out, melted the plastic housing and everything. I think the pin must have got stuck in the connectors and just had current run through it constantly until it got hot enought to start distorting the plastic.

Anyway, while I was trying to fix it a fuse blew when the wires hit the frame I'm pretty confident it was the fuse that's labelled indicators.

Had a look at it but all seems ok. Really making my head ache now. The only other things i can think is the current regulator is knacked but V unlikely as it would blow all the fuses surely, Other than that it has to be flasher relay throwing a fit. everytime it's gone the blinkers have been on. but doesn't happen everytime they are on.

Sure it'll be something really minor that smacks me in the face in a week or two.

[admin]

Where did you look for the chafs? Either side of the front seat where the retaining bolts go in? Also follow the loom done the left side of the sub frame to the ignition unit. There's a cross brace there that has a sharp edge and started to damage my loom. It's easier to see with the bodywork off. In fact that might be a good idea. Get all the bodywork off and follow the loom everywhere.

John

Have you checked for water in the indicators???? Try unplugging each of them and measure the resistance to see if one is different to all the rest..You never know.

[embee]

I'm with John Admin.

Your '99 will have the classic wiring harness chafing points.

The 2 seat fixing screws (shorten them slightly or simply fit washers under the heads to stop them hitting the harness behind, I also put a piece of rubber round the harness held with cable ties to protect it).

Under the pillion seat on the left side of the bike the harness loops round a frame bracket. I fitted some edging trim on the bracket, but plenty of pvc tape will do the job.

The blowing fuses and/or cutting out tends to be random since it depends on vibration and bumps etc.

Thanks everyone, took regulator off to see if that was the problem. ran for 50 miles and no blown fuses. Great new regulator it is then. bought one, fitted it went to put seat back on. Oh S!!!e. Left hand main bolt for seat had run straight through 3 wires, checked wiring diagram and yup, regulator,indicators and brake light wires all now burnt together.

So well done for top advice to all, and what a tit to me for not spotting it first time round . now i have 2 regulator/rectifiers and only 1 bike. Handy spare i spose.

unless someone needs it ??

[embee]

I'd keep hold of the reg/rec if I were you. They're not renowned for being the most reliable units in creation!

A fuse that blows regularly indicates a short. This is the painful part. You have to search the entire circuit involved from the fuse on out. No way around it.