94 hardbody lights shorting out

[Superdav]

Been a longtime reader here but now I got a problem I need help with. I bought a 94 after I had to give my 91 a graceful retirement after 800k miles and never leaving me stranded until the end and I actually smiled, anyway…

I got screwed on the 94, after driving it a few days my taillights and dash lights went out. Checked the fuse and it had a 30 amp in it. 30 amp! So I put a 10A back in it and drove it a few more days until it blew that fuse.

I have been over every inch of the pink/blue, grey/red and grey/blue wires and have found no shorts or damaged wire. The grey wires are dead and I found no shorts with multi-meter. The fender bulb sockets were broken when I bought it and after the first blown fuse I put the ones off the 91 on it. Didn’t help, while going over it I found an old fusible link plug that had been replaced that fell down in a crack. I asked the last owner about it and he claimed he knew nothing and had no problems, I now found that hard to believe. He claims everything was great.

Can I get some tips?

[Superdav]

Forgot to add when I took the air filter off I found #2 injector was fired off piggy tails from #3, still haven’t looked at that

[VStar650CL]

Intermittent shorts are the toughest task in the electrical world. First thing I would do is replace all the bulbs (yes, they can short internally) and inspect all the sockets carefully. If that doesn't help then you'll need to isolate which of the three harnesses involved is causing the problem. Since you know it was blowing a 30A, I'd start by temporarily installing inline fuses where the harnesses meet and at the illumination switch. Put a 30A in the fusebox, a 20A at Main-to-Chassis, a 20A where illumination comes out of the headlight switch, and a 10A at Chassis-to-Tail. Which one blows will tell you which harness (or circuit of the Main harness) has the issue, and you can then examine that in detail.

[whomadewho]

On the box ( rear passenger side ) follow the wiring harness for the tail lights that runs along the frame rail. At the end of the harness there is a junction block that connects the tail light assembly. Possible chance of a corroded or a broken wire creating a short, Also check the license plate lights, and the trailer plug if so equipped.

[whomadewho]

Aso front park lights/ signals are famous for electrical issues especially at the connectors and bulb sockets,

[Superdav]

Great play Vstar, I would have never thought of that
Whomadewho I didn’t mention but I did take the taillight harness off my 91 and put it on minus license plate lights that’s still an open plug
What’s the difference in a 91, 94 and 96 harness, gauge cluster? I saved a 96 harness that’s been cut into from a truck I bought for the motor in 2004 when I built my 91, Most of the 96 is there just missing some of those notorious plugs whomadewho mentions and a few other things (I’m not sure of what) the owner cut for some reason
I did buy some Amazon universal plugs I’ll put on it when I figure it out or I guess if I figure it out. I’m contemplating just getting rid of it and taking my loss if I can’t gain some ground soon

[whomadewho]

The fact that after you replaced the harness and the issue still exists should indicate the harness may not be the problem. You might try disconnecting the front park lights at the plug ins. I have delt with several where the wires in the connector where corroded. Check the actual park lights. I have seen when the lens is removed to replace the bulb the gasket gets ripped or forgotten allowing water to enter the assembly which causes the plug/ bulb to short. The bulb sockets are famous for corroding. Also there is a drain hole in the assembly. It's possible to install the park light with the drain hole on the top. As mentioned before check the bulbs first.

[whomadewho]

Not sure about the 1994, but on the 1996 - 1997 possibly on the 1995? On the left side (driver) there are 2 delays located in the left front corner directly below the air cleaner box. Check the relay plug.

[whomadewho]

Quick question.... Are the turn signals working?

[Superdav]

Quick question.... Are the turn signals working?

Turn signals all work, but they work really fast for some reason

[whomadewho]

Do the signals flash fast on both sides. Front/rear on one side only?

[whomadewho]

Try removing the park light bulbs and check each socket individually with a test light for power. Also check the bulb to make sure the bulb has two filaments. Possibly you have a single filament bulb. Another thought the wires going to the sockets are hooked up backward. Example.... When you activate the turn signals the power is going to the park light?

[whomadewho]

Few more thoughts/questions.... Do the 4 way flashers work? Check the fuseable link (positive battery) several wires provide power to various sources . Another thought... The fuse the keeps blowing... possibly the fuse wire is being used to power another device.. Example... Fog light.

[whomadewho]

A time saving tap.... Instead of continually replacing fuses purchase a 12 volt circuit breaker. They come in automatic or manual reset. Connect a long wire on each side of the circuit breaker and a crimp on wire end on the other end so you can plug it directly into the fuse holder.

[whomadewho]

A time saving tap.... Instead of continually replacing fuses purchase a 12 volt circuit breaker. They come in automatic or manual reset. Connect a long wire on each side of the circuit breaker and a crimp on wire end on the other end so you can plug it directly into the fuse holder.

[Niti QX4]

The circuit breaker is an awesome idea!

[Superdav]

Thanks all for the help but I finally got this taken care of, not fixed but fuses don’t blow, I cut wires to every interior light and taped them off.
ETA that I got new problems I’ll be needing help with