Constantly Blowing Fuse on Suzuki Intruder 125 2000

[Rockie]

So i have a suzuki intruder 125 2000, and i was riding perfectly find and pooof no lights, engine off. Ive come to realise that the fuse is blown in the starter relay, incoming end from battery. Even with ignition off, it will blow a fuse. uses 30 amp large fuse. Im completely stumped, gutted the whole wiring harness as much as i could out in the sticks and didnt find any issues. Anyone know what this could be?

[Simon Davey]

It could be the relay. 

Remove the relay,  and see if it still blows fuses. 

[_amw_]

It depends on the specifics of the wiring.  On a lot of bikes the 'starter relay fuse' (the 30 A one) is also the main fuse for the whole bike, so the feed going back to the fusebox is protected by the 'starter' fuse.  If your bike is like that, the the problem **could** be that the feed to the fusebox is somehow shorting out (on the frame or another wire or whatever) and blowing the main fuse.

 

Can you find a wiring diagram for the bike?

[RideWithStyles]

Id agree Definitely a short going on, as a general rule the starter motor and fuse is pretty much has the big/ main draw pretty much direct from the battery. Other than the starter, relay of something very close to it your leads to the cause is pretty short.

[Punts]

The 30A fuse feeds the regulator/rectifier with the r/w wire. Also the ignition switch and fuse box with the red wire. Unplug each one to see when it stops blowing the fuse, ( you can use smaller fuses to test as long as you don't turn the ignition on). 

[Copycat73]

burnt out winding on one of the phases of the alternator .. continuity test required on said alternator .. 

[Punts]

1 hour ago, Copycat73 said:

burnt out winding on one of the phases of the alternator .. continuity test required on said alternator .. 

If you disconnect the regulator/rectifier and it stops blowing fuses, it could be the alternator/stator