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hot fuses; help on electrical system
Topic Started: Thu Jul 10, 2008 1:46 am (665 Views)
kekahardr

I had a short in my electrical system. After fixing the problem I was running the bike with the fuses exposed to make sure everything was working Ok and I noticed the fuses were very warm. I thought I might have another short, but when I disconnected the headlight the fuses did not heat up. I have no idea how warm they got before as this is the first time I've felt the fuses when the bike was running.

Is this normal or should I be concerned? I took the bike for a short 15 minute ride and the fuse did not blow or anything, but after watching Final Destination I pictured the fuse starting the rubber case on fire and spreading to the gas tank with me going down the highway.

I've been thinking of changing the fuses from under the seat. The last time I blew a fuse it was twilight and I was only 10 miles from home so I just took the chance and drove home without headlights, outside fuses would have made it a simple mater to change them. Does anyone have any suggestions or experience with moving the fuse box.

My short was very interesting for anyone who is interested. I wasn't getting any power to the ignition and instruments, but after disconnecting the wires and plugging them back in I got power to the ignition swith, then I wasn't getting any power to the strater button, after disasembling the button and disconnecting the wires and pluging them back in I got power to it. Then I wasn't getting any power to the starter Relay, but after unplugging that, unplugging the starter circuit relay and plugging everything back in everything worked perfectly. I'm worried that everything works and I didn't fix anything, but I guess I just had a lot of bad connections all at once. The trouble started when my son took a fall in a very muddy trail, that might have had something to do with it. Bike is 2005 and has 10,150 miles on it.
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rick b
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Rick B
Electrical shorts have plagued my '04 a little too. I find that the battery connections under the seat are sometimes the culprit...working themselves loose.

I was out at the end of a dirt road a few months ago and got nothing when I went to fire it up again. Took off the seat and plastics (thank goodness the bike's got the little toolkit on board) and found the ground just a little loose. Mashed it back down, and it fired right up.
The small area where all this electrical is housed seems subject to a lot of jostling with the rider directly above it. Have been thinking about trying to protect it a little more.

Now I've got problems with the plug and play turn signal assembly. Have had it about a year and it's frying the 10A fuse under the seat repeatedly. Isolated the problem to that...I think. Going back to the OEM today to veryify for sure, but everything else under the seat looks clean, dry and insulated. Did you change your turn signal cluster, too? By chance?

Good luck.
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moabmc
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I have heard of a few headlight fuses blown with the stock switch. The common belief is that there is a momentary connection between the high and low position where both elements are powered at the same time. This causes an over load on the fuse and takes it out. Some have replaced the 10A fuse with a 15A and seemed to have stopped that problem. This says nothing about your aftermarket switch since I do not know if the same problem of powering both elements at once is a problem there. If you can't find a short or loose connection in your switch, you may try the 15A fuse trick to see if that helps. I'd be very careful if you do this to be aware or any heating problems with your wiring. I'd also be sure that all your electrical connections are clean and tight. A loose or dirty connection creates a lot of heat.
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