HELP!!! Main fuse keeps blowing

GanGREEN · #21 (**permalink**) 02-23-2010, 08:18 PM

I can get it to power on but as soon as I plug the headlight/starter switch it pops the fuse now but I have been moving wires around the fron so if there is a bare wire or short im sure I moved it by now! I rode it all day Saturday and as long as I didnt turn the lights on it was fine but now all the sudden it wont even do that!

GanGREEN · #22 (**permalink**) 02-23-2010, 08:21 PM

Ive only got 4 fuses left for the night so if you really want me to turn it on I will just tell me how and with what plugged in

GanGREEN · #23 (**permalink**) 02-23-2010, 09:16 PM

Well I just went out on thought Id try one more time to see what would happen, I plugged the headlight switch back in with the lights turned off, turned the key on, fuel pumped kicked on so I fired it up and let it warm up a little then throttled up like last time when it popped the fuse and nothing happened so I turned the lights on and they not only came on but were bright like they should be so I cycled them prolly 20 times and the fuse stayed good, moved the harness all over the place figuring it would pop and it didnt!!! Man I dont know what the issue is and I wish I cold have found something definitive cux now im gonna be gunshy to ride it!

nkeen07 · #24 (**permalink**) 02-23-2010, 11:56 PM

Quote: Originally Posted by GanGREEN

Well I just went out on thought Id try one more time to see what would happen, I plugged the headlight switch back in with the lights turned off, turned the key on, fuel pumped kicked on so I fired it up and let it warm up a little then throttled up like last time when it popped the fuse and nothing happened so I turned the lights on and they not only came on but were bright like they should be so I cycled them prolly 20 times and the fuse stayed good, moved the harness all over the place figuring it would pop and it didnt!!! Man I dont know what the issue is and I wish I cold have found something definitive cux now im gonna be gunshy to ride it!

That's weird man. I don't know how to explain that. There's an intermittent short somewhere. Just don't know where.

Duster · #25 (**permalink**) 02-24-2010, 12:30 AM

Quote: Originally Posted by nkeen07

Quote: Originally Posted by GanGREEN

Well I just went out on thought Id try one more time to see what would happen, I plugged the headlight switch back in with the lights turned off, turned the key on, fuel pumped kicked on so I fired it up and let it warm up a little then throttled up like last time when it popped the fuse and nothing happened so I turned the lights on and they not only came on but were bright like they should be so I cycled them prolly 20 times and the fuse stayed good, moved the harness all over the place figuring it would pop and it didnt!!! Man I dont know what the issue is and I wish I cold have found something definitive cux now im gonna be gunshy to ride it!

That's weird man. I don't know how to explain that. There's an intermittent short somewhere. Just don't know where.

Yep... something is touching something.

I actually kinda feel good now that I know more than I ever wanted to know about the KFX wiring schematic.

Look under the right upper frame rail under the gas tank.
Have a look-see at that Yellow/Red wire that plugs into the coil.
Make sure it is connected good and not touching the radiator or bare anywhere on the Y/R covering that is visible.

Next thing to have a look at is your fuel pump relay.
It also has a piggy coming into it off the Y/R wire.

Understand that this Y/R wire is the function of the thumb switch.
Lets power through to the coil and fuel pump relay from the key-on power wire (brown) and cuts this power to turn off the bike.

Your short is somewhere from the plug in the velcro, up the bars to the switch, in the switch, out to the headlights or tail light, or out the Y/R wire to the coil or fuel pump relay.

First thing to do though is try the following....

Try Key on... thumb switch off...
Then turn on headlights and work the brakes.... turn the handlebars, and wiggle the wires and whatnot.

Don't kill your battery though... lol...

If it's not out that way, you know to go the other way... Y/R wire.

Get some fuses man.
I stash a box of them in my velcro bag... lol...
Beats walking out of the woods over a fuse.

I should probably carry electrical tape too... lol...

GanGREEN · #26 (**permalink**) 02-24-2010, 07:40 AM

I'll try that tonight Duster. I have to stop and get some fuses after work, I can't tell you guys how much I appreciate all the help! I hope I can return the favor someday!

REEKERS529 · #27 (**permalink**) 02-24-2010, 12:45 PM

get a circuit breaker will save time and money!!

GanGREEN · #28 (**permalink**) 02-24-2010, 09:41 PM

I checked the coil wires and all was good so I taped everything back up and took it out and beat the shit out of it WITH the lights on and it didn't blow a fuse so I don't know what the deal was but it's good for now. Side note..... I LOVE the mega bomb header I put on yesterday too!! Too bad it's in the low 20's here or I'd still be riding! Thanks everyone for the insight and I'll keep ya posted as to it's durability!

nkeen07 · #29 (**permalink**) 02-25-2010, 12:14 AM

I hope it doesn't freak out on ya again man! Still doesn't make any sense to me man. Good to hear bout the Mega Bomb. What pipe are you runnin behind it?

GanGREEN · #30 (**permalink**) 02-27-2010, 01:24 PM

Well it's still going strong! And I'm just running a Lexx mxe behind it, nothin special but then again I operate on a tight budget, even got the megabomb for $220 shipped brand new off eBay cuz the guy had them listed wrong! Changed my front sprocket to a 15t also so now all I need is fir this snow to stop so I can enjoy it more but I still have the ol faithful Rincon with a 3" lift to get through the white stuff till then!