Fuses

[mrlmd1]

thedum - One way to convince the dealer to fix this once and for all is to avoid bad publicity. If this got out to the public it could seriously ruin his reputation for sales and service, Call your local newspaper and TV station, see if they want to do a human interest story about you and your failed dealings with them to solve your problem. Put up a You Tube video.Tell the dealer you are going to do this, it's not slander, it's the truth, and how they wont help you after they have been paid 3 times to work on your bike for the same problem. Have you talked to the manager of the dealership, or just to the guy at the service counter? You'll get a better response if you go to the top. And if they get your problem resolved, then you can cancel the newspaper and TV exposure.
It can't be that hard to fix, it's most likely a wire with frayed insulation somewhere, and you could find it yourself if you trace every wire carefully. Don't forget to look in the headlight bucket where the wires enter, maybe the rubber grommet is missing - could be something as stupid as that.

[alantf]

Originally Posted by thedum

I took it for a 45 mile ride attempt...and it kept blowing fuses again.

From what you've said, it seems to me that it's only happening on long rides ........... which is when the metal parts of the engine get HOT & start to expand. This expanded metal then touches the bare conductor that was exposed after the expanding hot metal melted the insulation, many moons ago. Seems to me (but it's only a guess!) that you should firstly give the cable loom a once over, to see where it passes really close (touching?) to any engine parts.

[burkbuilds]

I'll second what mrlmd1 recommends with an emphasis on going up the ladder until you get results. A lot of times just going up one level will get some results, it's possible that your problem is only known to the service department and they don't have the same incentive as the store manager or owner to see that a customer is taken care of. Unfortunately, the service department could care less if you ever come back, or whether you buy another bike off the showroom, but the store manager and the owner are very concerned about those things and they can get someone in the service department to put their best person on the job of getting your bike running right. You can be mad at the service manager all day and he really doesn't care, but if his boss is mad at him for not taking care of you he has much greater motivation to find the problem and fix it, or he might lose his job! If going higher up doesn't help, then go for the media pressure, but you seldom need to go to that scenario to get help, sometimes, but rarely.

[Easy Rider]

Originally Posted by alantf

This expanded metal then touches the bare conductor that was exposed after the expanding hot metal melted the insulation, many moons ago.

Very true but that is also when solid state components tend to fail......when HOT.
Exactly which fuse blew should narrow the search down to something reasonable.......should.