Blowing the Main Fuse???

[greenpill]

In need of help with an extremely annoying problem with the main fuse. Last weekend I was 5 minutes into a ride when the main fuse popped and the quad went dead. I decided to take it to the dealer since its under warranty to check it over and determine the if there were any shorts. Not surprisingly, the dealer found nothing and simply replaced the fuse. The quad started fine at the delearship. Yesterday I started the quad and headed to the trail when it once again popped the fuse one minute into the ride. I was replacing the fuse with a backup when the backup also popped even though the ignition and kill switch were off.

I have had issues with the battery discharging since it was brand new but this fuse issue is stumping me. I believe there is a short somewhere as in both cases the bike went dead once I got on the throttle. I have a power commander (pro-circuit map), Dasa full system, open airbox with Trinity/K&N filter. I also removed the headlights and tail lights (since May with no issue) and the radiator will kick on if the quad gets hot. Have any of you had this problem or at least where would you start? I'm good with suspension setups and general mechanical maintenance but the electrical stuff is a little more challenging. I doubt the dealer will help much as the DynoJet Power Commander is an easy place for them to put blame. One of the guys at the trail suggested reloading the map and checking for ground wire security.

Any help would be much appreciated as the best riding time here in Florida is slipping away. Thanks!

[shoey33]

when diagnosing an electrical problem you should simplify the problem, I would return as much of the quad to stock as possible and try a ride, this will help rule out add ons and thier installation issues. This will also help at the dealer as they cant blame what isnt there.

[bsanto]

Hi FLKawi,

I already had 2 times the same problem. Do you already have the solution to avoid this issue?

Thanks

[jerret125]

did you ever figure out this probelm. this happened to me today out in the middle of the woods. could not find any wires rubbed through. took me 6 fuses to make it back. it seemed like every time i let off the gas for a few it would die. finally i stayed on the throttle for the last fuse and a made it farther than before and it did not blow till i pulled up to my trailer and i let off the gas to see if it would blow and it did

[CarbSlayer]

Yeah i rode mine at winchesterbay this last weekend and it started popin the main 30A fuse...and i mean alot! went though 10 in one day....im pissed im takin it up to get looked at this week where i bought it....any info would help!

[g-eaton]

Did anyone fix their fuse blowing problem? Same thing happened to me today while on the trails. I had to hot wire the fuse so I could get home. Any help would be appreciated, so I can tell the dealer what to look for.

[g-eaton]

I think I have found the problem. Found the wiring that goes to the rear brake light rubbed through and shorting out on the frame. I looked at the wiring diagram and that would definitely blow the main fuse only. Everyone check your wiring at the rear brake light, could be an accident waiting to happen.

[jerret125]

<div class='quotetop'>QUOTE (28asedan @ Aug 10 2008, 06:06 PM) <{POST_SNAPBACK}></div>

Quote:

I think I have found the problem. Found the wiring that goes to the rear brake light rubbed through and shorting out on the frame. I looked at the wiring diagram and that would definitely blow the main fuse only. Everyone check your wiring at the rear brake light, could be an accident waiting to happen.[/b]

same thing to me but its mostly because i ziped tied it and it rubbed through there

[Kett18]

That seems to be the problem. My fuse problem was also related to wires for the brake light. My issue stemmed from the front brake wires.

[muff]

If you're blowing the main fuse you have a short somewhere.


You guys need to have your harnesses simplified. If you use it to race or don't use your headlights it's definitely the way to go. I've been doing quite a few Kawasaki harnesses and there are a lot of wires that can be removed.

Here's a picture of one that I have done.