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[pj57]

My 2005 Cherry is acting up. I can't figure out why it keeps blowing the 15A fuse that controls the speedo, tach, turn signals, stop light. If I replace the fuse and start it up everything works fine. Put the bike on gear and take off it blows.  I thought perhaps voltage regulator but I can rev the bike in idle with no problem. It's only when I put her in first and take off and it's immediate.  Speed sensor? This one has me stumped. Anybody else have this strange occurrence? Fix? Thanks, pj

[Twolanerider]

Just to clarify a bit Pete; just dropping it in gear doesn't correspond to an immediate pop of the fuse but moving the bike does?

[pj57]

That's correct Don - I can drop in in gear with no problem.  As soon as I release the clutch and pull away the fuse pops which is what leads me to believe the problem is in the speed sensor perhaps.

[Twolanerider]

That's a weird one Pete.  The speedo sensor really isn't "doing" anything differently moving or still.  The sensor is powered moving or stationary.  To isolate the sensor have you pulled the side cover and unplugged it?  You'd not have speedo or tach function but if the fuse still blew you'd at least know it wasn't the sensor.  If the fuse no longer popped you'd have gone a long way toward proving that either the questioned sensor or whatever harness you moved to unplug it was the culprit.

[pj57]

Don - great advice re checking the speed sensor...it's not that. I've isolated the short to somewhere inside the fairing. With the fairing cover off I took a spin around the block and no blown fuse. Put the cover back on fuse pops. So...it's just matter of finding a bare wire that's shorting when it's being forced down during cover installation. Should be loads of fun finding the needle in a haystack.   PJ

[Twolanerider]

Don - great advice re checking the speed sensor...it's not that. I've isolated the short to somewhere inside the fairing. With the fairing cover off I took a spin around the block and no blown fuse. Put the cover back on fuse pops. So...it's just matter of finding a bare wire that's shorting when it's being forced down during cover installation. Should be loads of fun finding the needle in a haystack.   PJ

While something being directly compressed by the fairing is a good jumping off point don't forget that the fairing might only be holding something slightly more tightly in place.  If so the chafed or split wire might be down around the neck somewhere too.  And it just gets pulled enough to short when the fairing holds it taut.

You probably don't have any before and after comparative photos.  But I'd look for any potential routing issue that might have come with the reassembly after the bike was stripped for its full frame color matching.  A chafe or pull might take a long time to eventually lead to a short.  Might not be it at all.  But tracing wires a finger full at a time is too likely what you'll end up doing if nothing obvious presents itself.

[pj57]

Good points Don. As painstaking as this is going to be, I think the best approach will be looking at the wiring diagram to see what wires are on the circuit and tracing them from fuse box.

[Twolanerider]

Good points Don. As painstaking as this is going to be, I think the best approach will be looking at the wiring diagram to see what wires are on the circuit and tracing them from fuse box.

Getting inside the loom will still mean handling everything in any given area though Pete.  Before tracing home runs from end to end I'd likely start looking at areas of compression under the fairing and areas of flex around the next.  Might get lucky.  Then when I didn't get lucky I'd start tearing everything else necessary to methodically check end to end.  Good luck with it man.  Hope you stumble in to the offending run quickly.

[pj57]

Don - lucky (and I mean lucky) me.  Found short...remember our HK retrofit project many moons ago? I neglected to insulate one of the jumper wires we used and it managed to find its way to ground. Looks like that project is still haunting me. Thanks for your support!  PJ

[Twolanerider]

Don - lucky (and I mean lucky) me.  Found short...remember our HK retrofit project many moons ago? I neglected to insulate one of the jumper wires we used and it managed to find its way to ground. Looks like that project is still haunting me. Thanks for your support!  PJ

Excellent news Pete.  So glad to read it didn't require tons more disassembly to find it.  So often such things end up being related to something done before.  Though almost a half a decade ago is a long time for a wire to lay around waiting to bite us in the ass.

Good news that it's fixed.  If I was further east the beer would be on me.