Turn signal failure, can't find the problem!

[ridenagain]

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.

[T-man]

If you are sure the switch isn't going to ground, then it sounds like an intermittent bare wire shorting out the system, perhaps making contact as you turn, or due to other causes like vibration, or both. Don't know which bike you have but makes no diff. It's a small chore, but I would rewire the turn signals from control relay, switch, and lights.

[Sgt Mike]

You state that fuses fail when you make turns. I would carefully inspect the wiring between the tank and the forks, sounds like you have a wire shorting in that area.

[Targetbuster]

Believe it or not, I had a similar problem when I first got my bike. Turned out to be a defective LIGHT BULB!! Amazing as it sounds the base of one of my turn signal bulbs was intermittently shorting out and blowing the fuse. I absolutely couldn't believe it but it was true. I would advise replacing all your bulbs. It can't hurt and doesn't cost much.

[ridenagain]

Thanks for the thoughts. Took your suggestions and took a close look at everything wiring wise up near the forks and tank and behind the headlight. Hopefully found the problem. The gray wire for the left front turn signal has a male end and the ends of the wires have a crimp type securing mechanism to them. Then there is a plastic / rubber boot over them when fully connected. It took 3 hours of time but I found one side of the factory crimp not crimped and it had finally poked through the plastic. Where it was sitting it was touching the headlight bucket assembly. I actually could not see it, I felt it when I put it back together. Taped it up nice and good and rode last night and turned the forks from side to side as much as possible when stopped and so far, no problems. Guess I’ll see.

[Sgt Mike]

Sounds like you found the culprit. Good on ya.