I have a 2006 FXDLI Lowrider that has been blowing its 40A Maxi fuse occasionally when starting.
Had this problem last year and thought it was due to a bad battery tender cable. Removed it and the fuse didn't blow at all the remainder of last year. Probably rode 1000 miles.
I have probably rode another 1000 miles so far this year (30 starts) and it blew last week for the first time.
Here is the symptom.
Turn ignition on- fine
Push start and it tries to turn over once and that's it. Fuse blown.
Put a new one in and it lasts for several months.
Is this the starter relay?
I know the bike has more electrical demand during the starting process.
It has never left me sit while running. Problem only occurs when starting. It's always a failed start.

 

If any wiring has been done since it first started, do a good check there first. Something has a short somewhere. I dont care how small it was or how much of it was done, anything with wiring. Check battery posts and ground real good.

 

Thanks. I was thinking that would come up. About 2 1/2 years ago I did a turn signal relocation for a removable sissy bar.
It required soldering which I did solid and used heat shrink tubing. I will go back through the wiring again.
I also installed an LED tail light 2 years ago. I will check that again too.
Thanks so much.

 

Check all the big cables from your battery to your starter focusing on loose connections and corrosion in the cable where they crimp into the terminals. If all this is good, think about your problem; is the fuse blowing during the initial start cycle before the engine hits or during the start cycle after the engine is starting to fire and crank up...

If it is blowing as soon as you start to crank, then I would suspect the starter is going bad or you have some funky cable connections. If it is blowing after the engine is cranking and starts firing up, then it could be the voltage regulator/charging system.

Also, do not forget to check your battery...a shorted battery might cause this if it is drawing too much current to recharge after the start cycle.

 

Not the relay, if it were, it would blow the 15 amp ignition fuse.

The starter will not cause a blown fuse, because there is no fuse between the starter and the battery (no motorcycle or car has a fused start circuit, it would take a zillion amp fuse).

This is a main circuit fuse, so the issue is somewhere between the output side of the main fuse, and the input side of the small fuses (this includes the ignition switch).