Need some help please. Main fuse keeps blowing

I am new to the forums but have had some sort of Interceptor since the 80's. Currently I have a 96 VFR that I have I have owned since 98 and yesterday while on the freeway everything shut down. No power to anything. I coasted it off the freeway and pushed it off the next ramp. I checked the owners manual and located the main fuse sure enough it was blown. I was happy to see I had a spare 30 amp fuse and thought no big deal. I installed it and as soon as I reconnected the 4 wire connecter onto the starter relay it poped. I did quite a bit of walking and located some more fuses. Thinking I had a wire shorting out I used the tool kit and stripped the plastics off my bike at a Holiday Inn parking lot. No luck! An expensive tow home and no luck.

I took it apart last night and on the connecter mentioned above(4P?) that goes on the starter relay there are 4 wires, red, red with a white stripe, green with a red strip and yellow with a red stripe. With this disconnected the main fuse does not blow. Am I correct in thinking that these 4 wires will all be possitive power wire? Because i connected power to the red wire directly, turned the ignition on and my dash lights and all other indicators illuminated like normal. When I got to the red with white striped wire it sparked so it indicated short to me and that goes to the RR. But it also does this when I put power to the green with red wirehe two wire that goes to the clitch diode and clutch switch.

I am missing something and any help wopuld be appreciated.

Thanks

 

Have you check all the connectors especially the head lights check for burn mark. Seem like it is short some where. Good luck and hope some other chimp in shortly.

 

Nothing looks burned. i checked the RR connection and it looks to have some heat discoloration but nothing burned. I will keep looking tonight.

Thanks

 

I would have thought if the main fuse is blowing, but none of the others up front have gone that it is
between the main fuse and the supply side of the front fuse box
or
RR has gone short circuit (my money is on that)
Try disconnecting the RR then replacing the main fuse and see if lights etc work without it blowing

 

I went through it last night and confirmed the RR is shorted out. No burned wires so now i have to figure out which way to go on the RR

 

check the stator coils are in spec...then new RR... get one with fins....mine has a 12v PC fan fitted also.

 

Which RR did you use? any pics?

Thanks

 

The previous owner replaced it and stuck the fan on so I dont have a part number etc
The connector looks quite fried but it all works...I'm in the process of making a replacement harness.
The one he fitted is like the after market one below. From all that I've read, before and after getting the bike, the connectors seem to be a big problem. They get corroded...resistance builds up then they fry the RR, battery and worse of all the stator coil$$$. Soon as I got the bike I pulled all the connectors and sprayed them with lube(acf50 etc). Do the RR one (obviously), the stator connector ... on the right on the fairing bracket...3 yellows...and the main connector on the battery fuse block.
Hell just do them all...I do this on any old vehicle I get.
I also fitted one of these
Low Battery Voltage Alternator Charge warning Alarm indicator bike Motorcycle G | eBay
and just wedged it above the clocks. Seems to show under-volts OK...it dips into the yellow at idle if the fan comes on....goes back to green if I blip the throttle.

 

Thanks richbike!

 

no probs...forgot to mention this bloke...TTFN
Wire My Bike