Blowing Ignition Fuse

[pmdsupply]

Good Day All,

I'm having a problem. I am blowing my 20amp ignition fuse. It blows when I'm slowing down after riding at moderate speeds. It almost killed me when it stalled on the edge of a cliff. The machine dies completly with no power what so ever. I have pulled it apart but can't find the problem. I have stripped all the heat protecting wraps on every wire I can find but nothing.... Any suggestions?

Thank you,
Paul

 

[TurboTime]

Good Day All,

I'm having a problem. I am blowing my 20amp ignition fuse. It blows when I'm slowing down after riding at moderate speeds. It almost killed me when it stalled on the edge of a cliff. The machine dies completly with no power what so ever. I have pulled it apart but can't find the problem. I have stripped all the heat protecting wraps on every wire I can find but nothing.... Any suggestions?

Thank you,
Paul

Check all the grounds from the starter, fuel pump, etc. Also follow the ignition fuse wire from the panel to where ever it ends up, then check that ground.. I do have the electrical schematics if you need them..

 

[Mtnviper]

Paul

One area to check is where the wiring harness passes over the left front motor mount. There is a small aluminum "knub" that sticks up from the motor mount. What can happen, is over time as the harness settles in it gets closer to the motor mount. Then the knub wears it's way into the harness and shorts the wiring to ground.
You can see the suspect area just behind the primary clutch and may have to pull the harness forward to see the knub.
What I did was cut the knub off with a hacksaw blade, filed the mount smooth and repaired the wiring harness.

Bill

 

[canoehead]

Paul

One area to check is where the wiring harness passes over the left front motor mount. There is a small aluminum "knub" that sticks up from the motor mount. What can happen, is over time as the harness settles in it gets closer to the motor mount. Then the knub wears it's way into the harness and shorts the wiring to ground.
You can see the suspect area just behind the primary clutch and may have to pull the harness forward to see the knub.
What I did was cut the knub off with a hacksaw blade, filed the mount smooth and repaired the wiring harness.

Bill

X2

 

[pmdsupply]

Thank you for your replies. I will work on it this weekend and will post what I find. Your help is greatly appreciated

Paul

 

[grizztracks]

The ignition fuse feeds through the handlebar kill switch to the ECU and ISC (idle speed control unit). Check the harness along the left side of the frame which has been a well documented trouble area. If you don't find any bare wires then I'd look at the kill switch then the ISC, The ISC is a solenoid valve that controls fuel when your not on the throttle. There have been a few reports of them failing but a code is normally displayed. You can check it's operation in the diagnostics mode which cycles it several times. I doubt the ECU is the problem.

http://www.ty4stroke.com/viewtopic.php?t=83992

 

[pmdsupply]

SOLVED

Thank you to everyone who posted. The answer was correct that it was behind the primary clutch. I will attach a photo for reference so that others may also learn of this annoying, time consuming, stress causing issue. I shaved off the "knub" as recommended, then I of course reinforced every wire with old tubing, duck tape, and then heat resistant tape. Now the task begins for putting the machine back together, so stand by for more posts as I have ripped the sled apart prior to asking how to fix it on here.

Once again, thank you.

Paul