Hi there, I'm about to have a minor breakdown. The electrical part is quite intense (my first time). But I'll manage.


I removed the complete cockpit, buttons etc. Replaced it for a custom made cockpit with LED's and switches. The flashing lights, brake light, horn etc are working fine. 
But when I turn the ignition key, hand brake, foot brake, clutch in, and then the start button, Fuse #5 blows every time. 


I changed the position of the battery, motronic and ignition control unit. So I think I made a cable mistake there. 


1. The thick cable tree of the motronic has a loose black cable, that one supposed to go to the mass of the engine right (minus of the battery)?
2. has the Ignition Control Unit some kind of mass cable too?
3. How can I test the Ignition Control Unit?


Any ideas?

leon83 wrote:But when I turn the ignition key, hand brake, foot brake, clutch in, and then the start button, Fuse #5 blows every time. 

If the fuse blows in the same moment you push the start button......
check the wiring between the start button and the starter relay.

Next step disconnect the connector with the two small wires at the starter
relay.....if the fuse still blows, the problem is in the wiring mentioned above
....if the fuse don't blow, the problem is internal in the starter relay.

Above I'm assuming that you don't have connected a lot of other this and
that to the same line the fuse protects.

did the test, thanks for that. The fuse still blows when I disconnect the plug. 

So what does that mean? Can it be the starter (brushes)?

From reading your post it sounds like you have done extensive rewiring of the bike.  The reason that I mention this is that normally the starter itself is not fused, so the starter brushes could not be the problem.  The starter relay however is fused normally I believe.  If this bike wasn't blowing fuses prior to your rewiring I would suspect a problem in your rewiring instead of a bad part.

I just cut everything of (no cockpit left). And made a new one, but haven't hooked it up yet. Besides the horn, flashing lights and backlight I'm starting with the start switch. So I don't think that that is a big problem isn't it?

So the only cable which can be wrong is the black cable coming from the ECU (motronic). I'm not sure if that one needs to be connected to the mass.

leon83 wrote:I just cut everything of (no cockpit left). And made a new one, but haven't hooked it up yet.

Please post a photo of the new loom you have made and how your bike looks at this stage of the project.

Here some photos.

leon83 wrote: The fuse still blows when I disconnect the plug. 

So what does that mean?

Does the fuse blow in the same moment you push the start button?

yes. Right at that moment.

I think the black cable which comes out of the big cable string of the ECU has to be connected somewhere else. But I don't know where.

I don't think the cable at the ECU have something to do with this problem
as it seems like you have a short between the starter button and starter relay.

Leave the small connector at the starter relay off.
Disconnect the big connector for the RHS switch assy...RHS under the tank.
At the connector on the main harness side bridge a couple of wires on the
side of the connector where the wires enter.
Bridge green to green/yellow. (kill switch)
Bridge black/green to black/yellow. (starter button)

Turn the ignition on, and off again after a couple of seconds.
If the fuse don't blow reconnect the connector at the starter relay to check
if we have connection all the way.
Turn on the ignition for a couple of seconds again, the starter should turn.

If the fuse don't blow the problem is in the RHS switch assy or related wiring
.......or we have to look elsewhere.

SO HAPPY!!!! and a bit ashamed as well.

So I made the new cockpit. Connect all the wire correctly fortunately. I connected all the plus cables together with nice ring sockets. But that bundle was touching my stainless steel cockpit cover. I didn't finished and closed it yet because I'm still working on it. So now put a nice piece of heat shrink over it and problem solved. Thanks everybody. This was a great help.