[Axeman88]

As could be predicted, my issue with blowing main fuses didn't fix itself, and progressed to the point where I couldn't ignore it any longer. Once I pulled off the Seat, Right Side Cover, and Fuel Tank, diagnosis and repair went quickly. It was, as I had anticipated, a fault in the insulation of the RED wire that goes from the Main Fuse to the Ignition Switch. This wire is live all the time since it's part of the main power circuit and in front of the ignition switch. Vibration had worn through the tape wrap around the harness and through the insulation at a point where the wire harness runs through the top engine mount. It was easily found and easily fixed. To repair, I used a little liquid electrical tape, then over-wrapped with electrical tape, adding a bit of bicycle innertube for extra protection at the wear point.

For this kind of job, I like to use a "beeper", that I put in the circuit in place of the fuse. This leaves my hands and eyes free to manipulate the harness into likely positions. With the ignition switch OFF, when the short is made, the circuit is completed, and the beeper beeps. This is much more efficient than using a meter or even a test light, and certainly better than blowing a bunch of fuses trial and error fashion.

Finding the short took less than two minutes. Maybe I got lucky, but the position seemed obvious. It's hard to imagine a harsher location than over the hottest point of the engine, and at a point of maximum vibration transmission. My next suspect would have been at the Ignition Switch. The wire bundle entering the Headlamp Housing, also looked like it could be better protected. Oh well, if it ain't broke, ......