A couple of months ago, I posted a message that I found my turn signals out during a pre-ride check. I replaced the fuse and a defective flasher relay and all was fine for 4 weeks. Since then, I have blown 6 more turn signal fuses. I have been trouble shooting the wiring after each fuse fails, but cannot reproduce the problem in the garage. I’m hoping someone can give me a little direction as to where to look next.
Here’s what’s been done so far.
1st fuse – replaced defective relay-relay had failed the pinpoint tests
2nd fuse – checked all 4 bulb holders and lead wires for corrosion – none found OK for 2 weeks.
3rd fuse – checked turn signal switch via volt meter – all in specs – was very clean and no loose wires. Allowed bike and signal to run for 30 minutes straight in garage, no failure. OK for 1 week
4th fuse – pulled junction box and inspected – no corrosion or frayed wires – die-electric grease to box contact points – inspected junction box seal and circuit board for visible cracks, none found. OK for 3 rides, 2 hours time.
5th fuse – checked wiring connectors to signal indicator bulb and engine cutoff switch – connector again very clear, no corrosion noted – die-electric grease applied to connector. Allowed bike and signal to run for 30 minutes straight in garage, again no failure. OK for 1 ride, 20 minutes.
6thfuse – 30 minutes ago when making a left hand turn, signal on. Yelled obscenities at bike! Didn’t help.
I can’t find a frayed wire, or bad connector on the whole circuit. The failure is now happening almost every time I ride, so it is becoming more frequent. Even so, I still can’t reproduce it in the garage. Any possibilities it is a failure in the junction box??
Running out of ideas. Thanks for any help or thoughts you may have.