Need help with electrical (starting/charging system) on '96
I hit a road block on getting my blade back together. Here's the current situation:
I went through most of the electrical system to get rid of melted and corroded wires and connectors that were on the bike when I bought it--interestingly enough, it would start in run when I first picked it up. I have replaced the R/R, its connector, and the battery to ground and battery to relay cables. I had initially replaced the starter relay (and its connector) as well, but I'm pretty sure I toasted it after connecting the cables backwards--the new relay no longer reads continuity between the battery-side post and the main fuse.... oops. So the old relay went back on, since it, as far as I know, is okay.
The problem that I am having is that it keeps blowing the main fuse as soon as I push the connector onto it. A few things to note on that:
1. With the starter cable and R/R disconnected, everything works fine. All lights and indicators work correctly and the relay clicks when I hit the start button. If I connect either, the fuse blows (with or without the key on.)
2. With the relay harness disconnected and the starter cable connected (R/R still disconnected) I get continuity but no current between the starter post and ground--that should be right, correct? Reconnect the relay and the fuse blows.
3. The starter turns over when jumped direct to battery.
4. With the battery connected, the starter cable disconnected, and the R/R connected, connecting the relay blows the fuse.
5. I get continuity only from ground to ground (negative to green) on the R/R connector, so sans a wonky pinout, the wiring should be good. Pin order follows the format that came with the R/R (yellow wires on the three top pins, hot (red) on the bottom left, and ground (green) on the bottom right.) I get continuity between yellows and no continuity between yellow/red, yellow/green, or red/green--at the connector.
All that said, I'm lost. There don't seem to be any problems with the wiring; if there were, I should have found a short to ground while checking continuity. Looking at the wiring diagrams, the system doesn't seem all too complex, and I should have been able to isolate the problem--the relay being the likely culprit. I would think, however, that it would consistently blow the fuse. That the electronics work without the starter and rectifier connected--but the fuse blows when EITHER is connected--throws me for a loop since there is no common link between them (that I see) BUT the ground.
Can the relay somehow short so awkwardly or should I look towards the R/R or something else?