What Damage have I done?????

[feelergaugephil]

1981 Suzuki GS1000G

I am sooooo ashamed of myself for this, the main fuse blew out, so after a few answers on here I bought a regulater/rectifier and decided to fix it last night,
All bolted up perfect and turned the ignition on "nothing", no lights or anything, so I looked and could see I had hadn't changed out the main fuse from it blowing last time, I got the thin screw driver and prized it out, well, it went downward and shorted...................

HUGE amount of smoke poured out of the CDI/igniter, I managed to pull the fuse out..
I took the tank off and checked all wires, the only thing I can find is the black/white stripe wire to the igniter is burnt out.
I checked the manual and looking at the wiring diagram it shows that the black wire (with white stripe) goes to two black wires, I stripped all the rear wiring and traced this burnt wire (no plastic left on this wire, but surrounding wires look to be OK)

I know I will need a new CDI, but could I have done other damage I am not aware of?????????????

[Dave8338]

Hard to say what can go with a direct short/ unfused connection. Start at the fuse box and work you way backward through all of the connections and wires...this may take a while, but at least you'll have checked everything. The only reason that I say to check everything, is that if you replace the R/R and something else is at issue, you may ruin your new R/R and have to start all over again. Electrical sucks...any insight as to what I'm working on right now... :shock: !!

[feelergaugephil]

The wiring diagram shows the R/R is not crossed lined to this main wire, the wires appear to be untouched by electrical current from the fuse short.

[Steve]

WOW, I have never seen a blown fuse do THAT much damage. :shock:

I don't know what all might have happened, but I might have an ignitor for you. What is the part number on it? Should be something like 32900-XXXXX. Fill in the Xs and I might be able to help you there.


.

[Dave8338]

There's a chance that you'll just need to replace the fried wire and all is fine...I hope that is the case. Make sure that the end connectors are intact as this is rarely the case.

[SqDancerLynn1]

If the CDI as you refer to it is fried Consider getting a dyna ign $150

[feelergaugephil]

I trailered my GS down to the local Yamaha dealers (yes, I know the mechanics) they double checked and 99% sure if I repair the B/W wire everything should be fine and replace the igniter........

Part# on the igniter is:-32900-45110

Somehow I pulled the fuse downward and shorted it out on the bottom of the lower fuse holder against the back plate this made 12V run straight through an unprotected ground.

[Suzuki mad]

Did something similar with the starter solenoid on a GS550E years back. The black and white earth wire just melted in front of my eye's.

Cut the burnt remains out of the loom and replaced each peice as I went. Bike started and ran fine without replacing anything else. I may have been lucky where it shorted out from, against the fuse box.

Suzuki mad

1981 GS1000ET
1983 GS(X)1100ESD
2002 GSF1200K1

[feelergaugephil]

FIXED!!!!!
I replaced the CDI and the one Black wire, it fired up instantly!!
I'll be careful next time if the fuse ever blows again.........
Quik question..............
With lights OFF (bike running) It's at 13.5 V.
With lights ON (bike running) It's at 12.9 V.

Is this right??????

[earlfor]

If the battery is decently charged, 12.9 as a "maintain" level should be fine. If the battery is down slightly, you can expect to see about 13.2. I dont see a problem with your readings. They're pretty close to what was common on my 1150 and I had an onboard voltmeter for constant monitoring.

E.

FIXED!!!!!
I replaced the CDI and the one Black wire, it fired up instantly!!
I'll be careful next time if the fuse ever blows again.........
Quik question..............
With lights OFF (bike running) It's at 13.5 V.
With lights ON (bike running) It's at 12.9 V.

Is this right??????