Ok, we need to back up to see areas where errors may had crept in. I suspect damage may have occurred well before alternator was replaced. Summary of what we know:
27-nov-23 https://www.st-owners.com/forums/threads/ecu-replaced-and-now-voltage-regulator-playing-up.185491/ -
- regulator failed and sent out too-high voltage, might have been caused by corroded or disconnected sense-line sending low-voltage back to regulator
- high-voltage fried battery, caused sizzling sound @ filling station
- brought to garage in France
- they did something, now it's blowing fuses (eeidiots!)
- they cut blk wire between 2 relays to stop blowing fuses (eeidiots!)
- bike has no power no longer works, bike shipped back to UK
- "auto technician" said ECU was fried
- ECU replaced
- RR output measured 18.3v @2500rpm
30-jan-24 https://www.st-owners.com/forums/threads/help-needed-to-reasemble-after-alternator-change.185889/ -
- alternator replaced
31-jan-24 https://www.st-owners.com/forums/threads/loosing-the-will-to-live.185897/ (this thread)
- smoke coming out fuel-pump earth wire
- fuel-pump earth and power wires melted
- replaced both wires and also melted
Extremely important thing is being able to distinguish between
cause and
effect (results, symptoms). Background story to illustrate. I get call from neighbor about water in his kitchen:
- he originally puts down towels to soak up water
- then he had to do laundry every day to get more clean dry towels
- he sets up 4am timer so he can get up and swap towels due to water
- water is increasing and he sets 3-hr timers to swap towels
- getting desperate, lack of sleep, etc., he cuts hole in kitchen floor to drain water
- he consults with irrigation engineer to set up dams and levees in kitchen to direct water towards hole
- etc. etc. etc.
Of course fighting symptoms/effects is losing battle because actual
cause of problem is ignored. All he had to do was
fix faucet leak under sink and that would be it!!! That's actual problem!!!
Same in this case, we need to look at
cause of blowing fuses, that's real problem! Frogs in France broke something trying to fix and caused fuse-blowing (probably fried ECU as well). Problem that caused blown-fuses was never found and repaired. Instead, they just clipped activation wire between BAS main-relay and fuel-pump relay so it doesn't power on bike. No more blown fuses, yay!!! But bike also doesn't work with no power either.
Now when bike was brought back, "auto electrician" claimed ECU was dead and replaced it. Fine... That's just
one problem, perhaps... But they didn't do anything about 2nd problem frogs caused, blowing fuses caused by short in wiring!!! I suspect this auto electrician "solved" this blowing-fuse problem by bypassing fuse or using extra large fuse that won't blow.
THAT's why fuel-pump wires are melting. Because frog's short is now sending extra amounts of current through wires that would've been blowing fuse originally. Problem is still there!
1. What fuse was it that was originally blowing in France?
2. Take look at that fuse (and all others for that matter). Has it been replaced with jumper or larger fuse???
None of these are proper solution to "fuse blowing". Find that short and fix it!!!
