Motorcycle Repair: Honda CA95 rectifier questions, starter solenoid, houseofmotorcycles

Question
Hi-I have a CA95 that is constantly blowing it's main fuse. It happens shortly after starting the bike and even sometimes when kicking it over. I have disconnected all non-essential (for running) equipment to isolate the problem and even with everything off, it blows the fuse even quicker after starting it. I have gone over Bill Silver's CD rom that I have for my CA77 as a reference and it seems to point me in the direction of the rectifier. It also seems that taking the electrical load off and running the bike may not be good for the rectifier, hence the quicker fuse blow. The first problem I need to solve - where is the rectifier?? I can't find it. Next, am I on the right track? Thanks!

Answer
Aloha, Robert....  Thanks for buying my CD!  Check this site for a wiring diagram for your Benly....
http://oldmanhonda.com/MC/WiringDiagrams/MCwiring.php

The rectifier is located up inside the frame, under the fuel tank/seat junction area. You will have to pull the battery and probably the air filter to access the electrical parts up inside. It is up where the coil mounts.
http://houseofmotorcycles.bikebandit.com/Honda-Motorcycle-CA95-1959/o/m1937#

When the ignition switch is ON, in the first position, just the ignition, starter solenoid, horn, neutral light and brake light circuits should be lit up. Disconnect one thing at a time to see if you have specific shorts on those related components.
Horns can short out or the wiring connectors to them. Handlebar switches can rotate on the handlebars and pinch the wiring, causing short circuits. Look inside the headlight housing for loose connections, wire connectors with the sleeves pulled back touching ground or cross wiring issues.

The rectifier output leads to the battery. That lead isn't fused, though. You have a short somewhere in the Red wire going to the ignition switch or the black (and other) wires coming out of the switch headed for the accessories.

With lesser electrical loads, the output of the stator to the rectifier will be greater to charge the battery. Be sure you have a fully charged battery when running the bike.

A 40 year old rectifier is often a source for charging system woes, but you have to remove it and test it to be sure. If it looks overheated or melted, then it needs replacing, but check ALL the wiring on the bike for any wires that might be pinched or have exposed insulation that could be causing a short, as well.

Bill Silver....