You said your flasher flashes when the test light was in it. So it's good. You need to start over with your wiring. Look at each wire to see that it goes to the correct component. NO MATTER WHAT COLOR IT IS. The new switch probably has certain colors and a diagram on how to wire. But you can't trust that the existing wires, that you are attaching to, are the correct colors. Wire it by function. When you do this, do it with an eye that it is wrong, not that you did everything right. If you don't, you will miss the mis-wire again. You already know something is wrong, so find it. Chances are that the switch is good, so it's the hook up. If you have also messed with other lighting wiring and grounds, could be other wiring mistakes.
Questions:
How did you attach existing wires to the new turn signal switch? By colors? by a connector? figured it out by function? Rethink and double check this part. With it hooked up right now, do you have brake lights? Did you install dual filament bulbs in rear or do you have separate lights? What exact fuse was blown?
Commentary not aimed at you:
Assumptions and egos do not belong in troubleshooting. Don't trust any wire or wiring, unless you absolutely know where it goes.
I know you know how the 7 wire turn signal is wired. Is it the 7 wire, 12V sold by J. Carter? Just trying to jog the procedure to help you discover something. You can't simply match colors and expect it to work.
1. A wire to flasher P
2. A wire to flasher L
3. A wire to stop light switch
4. A wire to Front left bulb directly
5. A wire to Front right bulb directly
6. A wire to Rear left bulb brake filament directly
7. A wire to Rear right bulb brake filament directly
Notes:
None of the above go thru the headlight switch.
The turn signal switch has three power inputs. Two from flasher, one from brake switch.
The turn signal switch has four outputs. front and rear light bulbs. 3+4=7. It has a fifth "internal output" to the pilot bulb.
Flasher gets ignition hot to X.
Other side of stop switch gets batt pos (hot).
As said, the pilot light should not be lit, only when flashing occurs. That's your big hint to a miswire or malfunctioning switch, can't return a disassembled switch.
All bulb sockets need to be grounded to chassis thru their metal to metal contact to the chassis or frame and back to the neg battery post thru your various ground straps.
Check all four bulbs to see that they light. All filaments.
It sounds like taking switch apart, not getting it back together properly, pinching wires at the column, pilot on and a blown fuse could indicate you are rushing thru this or not studying the issues first. Slow down. Taking a new turn signal switch apart is a bad idea. It's entire function can be checked with a continuity test.
There is no doubt you will fix it shortly. It is just a small mix up somewhere.
