I keep blowing the same fuse? - Road Star Warrior Forum : Yamaha Star Warrior Forums

Hydro · 12-31-2012, 10:50 AM

A few weeks ago I blew the Ignition Fuse.
Replaced it...bike started and ran fine.
A few days later same fuse blew again.
Again I replaced it...bike started and ran fine.
A day or two ago the same fuse blew again.
I'll take any thoughts or suggestions that you may have.

gilly · 12-31-2012, 11:16 AM

I would have to say you have a wire shorting out somewhere but it must be due to vibration considering it does not blow immediately when you plug it in. I would trace the wires from the blown fuse back till i found something.

arizonawarrior · 12-31-2012, 11:19 AM

Especially trace in areas where a mod or repair has been done. Possibly the internal handlebar wiring.

skybejef · 12-31-2012, 11:52 AM

Were there any changes/mods/repairs done around the time the problem started? Any mods done involving wiring at anytime in the past?
I can see from pictures you have a heavily modified warrior.
As stated above by gilly and arizonawarrior time to start tracing wires. If you have a voltmeter it would be a good time to break it out.

Hydro · 12-31-2012, 03:26 PM

I appreciate the input. I'm headed out to get into it. I'll let you know what I find.

Hydro · 12-31-2012, 06:11 PM

skybejef: The problem started 3-4 weeks ago. The last tinkering I did was Battery Maintainer & Pig Tail, HID's and LED's back in October. It was all plug and play. The only activity in and around the wiring harness was making the connections to the battery.

gilly: that's exactly what I'm doing now and hoping for an easy find.

arizonawarrior: I thought of that...this electrical stuff is new to me other than my golf cart building experience. I 've attached a few pic's. In the morning I'm going to remove the gas tank and continue unwrapping and checking.

Any thoughts please feel to share and thanks

BiggG · 12-31-2012, 06:21 PM

Do you have the battery pigtail connector cover installed when riding ?
I always make sure my cover is on and I also secure the pigtail in place using the rubber strap on the top of the battery.

If not that I'm almost willing to bet the issue is with the blue Tail light wire grounding out somewhere's in your rear fender.

Hydro · 12-31-2012, 06:29 PM

Hey BiggG
"Do you have the battery pigtail connector cover installed when riding?"
Yes the pigtail is always wired up and cap is on unless bike is on the maintainer. Pigtail is secured to frame via Velcro while riding.

You said: If not that I'm almost willing to bet the issue is with the blue Tail light wire grounding out somewhere's in your rear fender.

My Question: It's the Ignition fuse that keeps blowing. Wouldn't a short in the tail light wire blow the Head Light fuse?

LeaderDuece · 12-31-2012, 06:53 PM

I sent some thoughts in a pm...

gilly · 12-31-2012, 07:24 PM

Your ignition fuse 10 amp is powered from the key through the brown with a blue stripe wire and goes to your kill switch, starter relay, and then goes to the ECU to pin 8 and 39 just to give you an idea what wires maybe to look for. You could also have a problem at the fuse area since you were working near there when hooking up your pig tail.

12-31-2012, 10:50 AM	#1 (permalink)
Hydro Senior Member Join Date: Nov 2012 Location: NC Posts: 237	I keep blowing the same fuse? A few weeks ago I blew the Ignition Fuse. Replaced it...bike started and ran fine. A few days later same fuse blew again. Again I replaced it...bike started and ran fine. A day or two ago the same fuse blew again. I'll take any thoughts or suggestions that you may have. __________________ Whether you think you can...or you think you can't. You're right.

12-31-2012, 11:16 AM	#2 (permalink)
gilly Senior Member Join Date: Aug 2007 Location: Perdido Bch. Al. Posts: 2,200	I would have to say you have a wire shorting out somewhere but it must be due to vibration considering it does not blow immediately when you plug it in. I would trace the wires from the blown fuse back till i found something. __________________

12-31-2012, 11:19 AM	#3 (permalink)
arizonawarrior Super Moderator Join Date: Jan 2005 Location: Near Mt Hood Oregon Posts: 18,187 Blog Entries: 5	Especially trace in areas where a mod or repair has been done. Possibly the internal handlebar wiring. __________________ My Pics Great Members Popular Mods Model Year Differences Group Rides WyomingDIY KyleNV Technical Last edited by arizonawarrior; 12-31-2012 at 11:59 AM.

12-31-2012, 03:26 PM	#5 (permalink)
Hydro Senior Member Join Date: Nov 2012 Location: NC Posts: 237	I appreciate the input. I'm headed out to get into it. I'll let you know what I find. __________________ Whether you think you can...or you think you can't. You're right.

12-31-2012, 06:29 PM	#8 (permalink)
Hydro Senior Member Join Date: Nov 2012 Location: NC Posts: 237	Hey BiggG "Do you have the battery pigtail connector cover installed when riding?" Yes the pigtail is always wired up and cap is on unless bike is on the maintainer. Pigtail is secured to frame via Velcro while riding. You said: If not that I'm almost willing to bet the issue is with the blue Tail light wire grounding out somewhere's in your rear fender. My Question: It's the Ignition fuse that keeps blowing. Wouldn't a short in the tail light wire blow the Head Light fuse? __________________ Whether you think you can...or you think you can't. You're right.

12-31-2012, 11:52 AM	#4 (permalink)
skybejef Senior Member Join Date: Apr 2008 Location: Sioux Falls Posts: 929	Were there any changes/mods/repairs done around the time the problem started? Any mods done involving wiring at anytime in the past? I can see from pictures you have a heavily modified warrior. As stated above by gilly and arizonawarrior time to start tracing wires. If you have a voltmeter it would be a good time to break it out.

12-31-2012, 06:21 PM	#7 (permalink)
BiggG Senior Member Join Date: May 2011 Location: Maryland Posts: 1,731	Do you have the battery pigtail connector cover installed when riding ? I always make sure my cover is on and I also secure the pigtail in place using the rubber strap on the top of the battery. If not that I'm almost willing to bet the issue is with the blue Tail light wire grounding out somewhere's in your rear fender.

12-31-2012, 06:53 PM	#9 (permalink)
LeaderDuece Senior Member Join Date: Feb 2011 Location: Clarksville, Tennessee Posts: 8,207 Blog Entries: 11	I sent some thoughts in a pm... __________________ Redhorse Mods Popular Mods DIY Mods Internal Wiring Manuals&Maps Warrior Brothers World Wide Map

12-31-2012, 07:24 PM	#10 (permalink)
gilly Senior Member Join Date: Aug 2007 Location: Perdido Bch. Al. Posts: 2,200	Your ignition fuse 10 amp is powered from the key through the brown with a blue stripe wire and goes to your kill switch, starter relay, and then goes to the ECU to pin 8 and 39 just to give you an idea what wires maybe to look for. You could also have a problem at the fuse area since you were working near there when hooking up your pig tail. __________________

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