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Desperate for Electrical Help Ignition Fuse Keeps Blowing(long read)

I just wonder why all the plugs on our Japan build sleds are sealed which molded in triple seals and the Yamacat does not even have dielectric grease from factory. Most of the consumers don’t take there purchase home, tear it down and do all the nessesary things to not have issues out in the middle of nowhere. On these sleds you travel in half an hour what will take all day to walk back from. The deeper the snow the slower the walk.
 

Just let me add something here. I really love my Viper. I am very resourceful and will fix all the little things that I am not happy with. I love the look, ride, seating position. I will tinker and change some of the things that bother me. I tend to keep my sleds for a long time. The chain case is my focus this summer. Install drain and fill plugs that are accessible. The chain adjuster is going to need more thought. I am not slamming this sled just a little bit anoyed. I will get it right.
 
Handy said:
Just let me add something here. I really love my Viper. I am very resourceful and will fix all the little things that I am not happy with. I love the look, ride, seating position. I will tinker and change some of the things that bother me. I tend to keep my sleds for a long time. The chain case is my focus this summer. Install drain and fill plugs that are accessible. The chain adjuster is going to need more thought. I am not slamming this sled just a little bit anoyed. I will get it right.
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It's a love hate thing for sure. If we all were seriously concerned about reliability we would be riding fan cooled 250cc single cylinder carbed sleds like a old Enticer with a 2x4 compartment under seat for spare parts. Used to do that but now realize even a walk or overnight in freezing cold as long as fire it's better than work! All this tech is so nice worth the risk but I don't ride in Alaska or some other remote area.
 
cannondale27 said:
Well something worked because I got 280mi on today and for local that's a lot. Beat the tar out of it and it ran flawlessly. Thank you guys for all the suggestions. Not sure what repair or freak circumstances blew all those fuses but I am calling it good. Really appreciate the encouragement especially.
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So you aren't really sure what the problem was? That's what nightmares are made of!
 
Handy said:
Just let me add something here. I really love my Viper. I am very resourceful and will fix all the little things that I am not happy with. I love the look, ride, seating position. I will tinker and change some of the things that bother me. I tend to keep my sleds for a long time. The chain case is my focus this summer. Install drain and fill plugs that are accessible. The chain adjuster is going to need more thought. I am not slamming this sled just a little bit anoyed. I will get it right.
Click to expand...
If you do that successfully, with the chaincase, please post it! I love my YamaCat and that's one of the biggest gripes I have about it! Itll take the reverse actuator out if the equation. Plus, dropping the track is a pain...
 
Kkurz said:
If you do that successfully, with the chaincase, please post it! I love my YamaCat and that's one of the biggest gripes I have about it! Itll take the reverse actuator out if the equation. Plus, dropping the track is a pain...
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Not me. Chaincase needs to be inspected yearly and oil lasts that long too.
 
I have been looking over the wiring dia the red and white wire coming off that fuse goes to the ign switch and then turns into a red and velvet wire then that goes to the emergency stop switch the tail light relay and head light relay and also fuel pump relays
 
that's a bummer. The good news is that if it's a consistent problem you might be able to start isolating sections of wiring with an ohmeter. It sounds a like something is shorted to ground.
 
sxr70001 said:
that's a bummer. The good news is that if it's a consistent problem you might be able to start isolating sections of wiring with an ohmeter. It sounds a like something is shorted to ground.
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Yes its consistant. Scared to take hood off and have it stop blowing fuses like it did last time but running out of things to check with hood still on.
 
CobraJet is sending me a test kit the Auto Techs use for finding things like this. I am not going to remove hood out of fear of it stopping the fuse blowing like last time. Have tested about all I can with hood on.
 
cannondale27 said:
Yes its consistant. Scared to take hood off and have it stop blowing fuses like it did last time but running out of things to check with hood still on.
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got the x wife a 94 Puma Delux and first weekend out the wiring harness rubbed through and shorted everything out...…… I was on a 87 SRV 540 at the time ported, polished, shaved head, clutched, fast and bullet proof..... I swore no more Artic Cats and yet here we are , but I digress
 
srvfan said:
got the x wife a 94 Puma Delux and first weekend out the wiring harness rubbed through and shorted everything out...…… I was on a 87 SRV 540 at the time ported, polished, shaved head, clutched, fast and bullet proof..... I swore no more Artic Cats and yet here we are , but I digress
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My SRX had a major rub through also so not blaming the Cat in it Yet. Very well may be my own doing.
 
did you look at that spot under the fuse box that some of the guys were talking about?
 
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