99 Shadow Ace 750 blowing fuse!

[93ltd]

Hey Guys,

I have a 99 Honda Shadow Ace Deluxe 750 that keeps blowing the 30 amp main fuse.......this fuse blows right when I try to reconnect the 4P starter relay connector that houses the fuse?? I don't know much about the mechanics of bikes but I do have the service manual for it.

When I put the first 30 amp fuse in it it didn't blow right away, and I was able to start the bike, everything seemed ok, then I notice that smoke started to come from the regulator/rectifier I immediately shut off the bike and checked the source for the smoke which turned out to be some of the rubber tubing that houses some wiring was touching it and started to melt - but not bad at all, just got hot enough to smoke, no damage to the wiring there or even the rubber tubing.

Once I moved the wiring from touching the regulator I turned on the key and once again had no power, I pulled the fuse again to check and it to had blown. Now when I put a new fuse in I just pops it as soon as I go to reconnect it. Could it be the regulator??? the starter relay switch or something else.

The service manual of course does not give any troubleshooting info reagarding the blown fuse condition

Any and all help is greatly appreciated

[chubster2003]

there is a direct short somewhere... now you have to find it... i would check that regulator that was smoking.. look over it carefully and take it apart.. check for blown capacitors or discoloration on board/soder... make sure no wire's melted together or are bare... that kind of thing... if nothing... try to find a used on ebay or a local salvage (junk) yard.. maybe a pull-N-save.. dontknow if these places would have wrecked bikes but if ya go to a dealer its prolly going to be really expensive (for example.. the peg brace on my bike broke... dealer wanted 120$.. you can get em off ebay for like 20$ with shipping... major difference)

anyway good luck hope you find the short or whatever it may be

Welcome to the Forums

[93ltd]

Hey Chubster2003,

I took the regulator off as you suggested and I did notice a very small rip in the rubber insulating material that covers what I assume to be the cilrcuts inside......this small tear is in the exact location of where the smoke was coming from. do you think that the smoke that I thought was coming from the wire loom that was touching it was infact just coming from the regulator, as it fried some components inside itself?

[chubster2003]

ok now what i would do.... but prolly not recomended by others... is to cut away the rubber isulating .. you could replace this later with say an old bicycle tire and electrical tape... and check it out.. if any wire is showing cut out and replace wiring.. if not keep uncovering untill you either get through all the wire or find it...

dont just look for bar wire.. look for discoloration or stretching.. anything out of the ordinary...

and like i said before.. if it seems to only come from the regulator.. IF you can take it apart do so and see if anything is fried.. if you cant.. try and find one off a parts bike.. say at a junk yard or something.. or take it to a dealership and see if they have any way of testing it ..

hope this helps...