Issue
10amp ignition fuse blows when power is on and killswitch is disengaged, often blows insantly, never get as far as the starter motor coming into action. No visible short connections found.
Long story
Riding home from work on Thursday my AL5 650XT cut out. I coasted into the next turning and began investigating. My 10amp ignition fuse had blown and all others were intact. So I put the spare 10amp fuse in from the fuxebox housing, turned the bike one, seemed fine, then pulled the clutch in and hit the ignition and nothing happened at all, no starter motor attempt. Checked the replaced fuse and that had now blown. Thought it must have blown without me realising before I even tried to start the motor, which I didn't expect. So I got the spare spare 10amp fuse out my backpack and put that in place, with the ingtion off and killswitch engaged. Then watching and listening for the fuse blowing (over busy traffic), I turned the key and the fuse remained intact so I disengaged the killswitch, still fine, them as I was about to try and start the engine but before doing so, the fuse went again.
Out of fuses I got an AA recovery organised and started frmoving fairings looking for a short. couldn't find anything dodgy within site. Almost two hours later the AA arrives, a young bloke whos been with them less than a month and was happy to tell me that he had no previous experience with motorbikes. I explained the situation and what I'd done so far. He then checked everything I had checked, insualted a couple of tiny wires that were almost rubbing through against a frame fairing mount on the LHS. Lost for further ideas he put a new fuse in to look at when it blows again, this time it started like there was no issues! The AA man logged the job as complete and offered to follow me home the remaining several miles just to be sure. I wasn't very satisfied, sure there was still a fault that was just tempermental, probably hard to find and I would soon be broken down again.
I rode about 50m and the bike cut out again! We blew through nearly all his 10amp fuses trying various things. Weird that the ingition fuse wouldn't blow with the killswitch engaged but onced the killswitch was disengaged it could blow instantly, in a few moments, or not untill you go the start the engine but never lasting so long for the starter motor to kick in. AA man gave up and organised for a third party recovery vehicle to get the bike home. He said his AA van was capable of transporting the bike but he hadn't been shown how to use the equipment.
Help?
Today my Father and I have taken the fairings, petrol tank ,air box, etc. off to check any wires that could be shorting but we havn't found anything.
Firstly, can anyone provide me with a wiring diagram for this bike? I can't seem to find one online.
Has anyone had a similar experience and discovered a short connection that we may have missed?
If it's not a short connection, what else is it likely to be, or what are the next steps to take?
Any help would br greatly appreciated, thank in advance,
Pete.