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Blowing fuses AGAIN!!!!!!!!!!!!!!!

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Old Mar 18, 2012 | 03:50 PM
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Default Blowing fuses AGAIN!!!!!!!!!!!!!!!

Last summer I would start the bike when the bike was cold. No problem. Then I would ride for an hour and stop. Then try to restart the bike and it would blow the igniton fuse as soon as I hit the start button. I replaced the black box that plugs into the back of the fuse box. It seemed to work.

My stator also went bad last year. I replaced the stator, and got a new battery over the winter. I have been out 3 times this year so far, and all was well. Until today. I went for a ride. It started right up, I went to the local tire place to fill my tires. (About 3 miles away) I shut it off and filled the tires. It started right up again. I rode for another hour and stopped for fuel. I went to start it again and DAMNIT IF THAT DAMN FUSE DIDN'T BLOW AGAIN!!!!!!!!! I replaced it 6 times and it blew again all 6 times. I had to have it towed home.

What could be causing this? I have been told it must be a short somewhere. Well where should I start looking? Is there a common place shorts happen?
 
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Old Mar 18, 2012 | 04:27 PM
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Did you change your grips or handle bars? Could be up at the controls.
 
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Old Mar 18, 2012 | 05:21 PM
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Originally Posted by Mike07FLHTC
Did you change your grips or handle bars? Could be up at the controls.
No. I haven't done anything to the bars.
 
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Old Mar 18, 2012 | 05:31 PM
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I had the same problem with that fuse and my turn signal fuses couldn't figure it out then one day changing out my head light I cut the plastic casing from the head light wires they use to hide the wires full of water and it was shifting out the bike I removed the casing and haven't had a problem since not saying same on your bike but check if there's water in the wiring casing
 
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Old Mar 18, 2012 | 05:32 PM
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Does it blow right away or does the motor start to turn over first then it blows? Just wondering if your starter is going and draws too much power when it's hot.
 
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Old Mar 18, 2012 | 05:36 PM
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Originally Posted by HOTLAP
Does it blow right away or does the motor start to turn over first then it blows? Just wondering if your starter is going and draws too much power when it's hot.
It blows as soon as I hit the start button. No engine movement or starter movement at all. I hit the button and "CLICK" the fuse blows
 
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Old Mar 18, 2012 | 05:38 PM
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Originally Posted by armymedic54
I had the same problem with that fuse and my turn signal fuses couldn't figure it out then one day changing out my head light I cut the plastic casing from the head light wires they use to hide the wires full of water and it was shifting out the bike I removed the casing and haven't had a problem since not saying same on your bike but check if there's water in the wiring casing
I did have a problem with the headlight a couple years ago. It melted the plastic around the connection. Were the light plugs into the harness got fried and melted. I replaced it, but I haven't checked it since. Maybe I will look there first

THANKS
 
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Old Mar 18, 2012 | 06:21 PM
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I did a couple of thing at one time to my bike,installed a battery tender hook up cable Tank lift, changed risers and changed handle bars. Bike worked fine for about a week then my headlight when out and my bike ran like crap. Turned out my dumb *** tighted down the riser on the left side on the blinker wire.Bikes fuse kept popping like yours, went over the entire harness, headlight wiring and every area I could think of except in the area of the risers. Finally broke down and brought it to my mechanic who did a fast walk around while asking what I did. He found it, I fix it all's working well. So check and follow your wires, if there's a break somewhere that could be your problem.

I also had the headlight problem as well but it didn't effect anything but the headlight.
Good Luck figuring your problem out.
 
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Old Mar 19, 2012 | 03:15 AM
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If ya can't get it sorted out, I'll be glad to take a look at it for ya. I am in Elyria.
 
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Old Mar 28, 2012 | 04:30 PM
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Thanks for the help guys. This forum is the BEST. I took off the bars and the headlight. The wire harness that goes into the headlight had cut wires. The rubber gromet that covers the hole edges on the back of the headlight had moved. The wires were rubbing on the exposed metal edge. And the wires has almost worn all the way through.

I replaced a couple of wires and made sure the gromet was covering the exposed metal edge. I took it for a 2 hour ride today. Got it nice and hot. And I came home, and started it about 5 times and the fuse didn't blow. I hope the problem is over.

ThANKS AGAIN!!!!!!!!
 
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