dexter
TY 4 Stroke Master
has anyone had their 20 amp headlight fuse blow? I was on ride this weekend and the fuse popped while sitting at a stop. I replaced the fuse and she ran with no issues for 80 plus miles. Started it the next morning and within 10 seconds pop again. I am assuming I have a chaffed wire somewhere. Can anyone tell me what areas are common so I can narrow my search down. Thanks!
Honk
TY 4 Stroke Master
check wires in the steering colum area.
dexter
TY 4 Stroke Master
just checked the wires in the steering column area and nothing seems to be rubbed or cut through. I also checked area in the bulkhead under the tool kit. Both areas show some rubbing but nothing through the protective sheathing. I am an electrical idiot so I dont know where to go from here. any advice???
mine was doing the same thing this weekend, i pulled the tool box and found that the blue wire and yellow wire were rubbed to the bare wire. i'm pretty sure that was my problem
dexter
TY 4 Stroke Master
can you give me a description as to where under the tool box.... inside the covering at the nose?? down by the electrical box?? did you have to cut into the sheath to find this? thanks for the help as this is killing me!! 
03RX1-ER-LE
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Happend last week on my wifes sled after 5000 miles, the chafe is next to the tool box (right side)where the harness lays on a "SHARP" metal bracket. The harness may look ok at first glance, but when you run your finger down it you will feel a flat spot in the sheating. It does not take much rub for it to short, a pin hole size hole will short out under the right conditions. Rap electrical tape around harness and split a rubber hose and lay on metal bracket with tie straps. When I go back up to my cabin this weekend I will try and remember to take my camera and take a photo.
mine was also in the same place.their are 3 plug connectors, 1 clear and 2 black. mine was on the bigger of the 2 blacks, i think 6 wires in the plug. the sheathing was real loose on those wires, and i found the 2 that were being rubbed close to the plug 1 blue, and 1 yellow, very small but you could see the bare wires
rbailey3711
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Headlights on RX body style
Thought I'd add about the same problem I had to fix this past Sunday on my '04 RX Warrior.
If the headlamp 20A fuse has been blowing while riding, you may have experienced the same problem I did; I only had one spare 20A fuse when it blew the second time and had to ride in the middle of our group. I also posted this on John Dee's website.
In the front of the sled:
1. You have to unscrew and remove the toolbox.
2. Unplug the two connectors on the rectifier/regulator assembly [very front of frame]. This makes it easier to wrap the wires with tape. There is a "push pin" release for the connectors; you'll have to feel for them since they face the front of the sled.
3. Look for the headlight wires, they are blue/green and yellow.
If you have the same problem:
4. Find the wire that has the insulation rubbed off and wrap it with electrical tape; it could be both wires. I also wrapped mine with the other wires to have more insulation on the leads.
5. Lift the wiring harnesses up and using a cable tie, tie the harnesses to the upper part of the opening; I found a slot next to the bolt, as you look down, to run the cable tie through. Also, you can cut a 1/4" or 3/8" hose and place it over the sharp edge of the frame before you reinstall the toolbox.
6. Reconnect the plugs, reinstall the toolbox, replace the fuse and you should be good to go.
It took me about three hours to find the problem because I started at the "moving" parts in the steering column end of the wires.
Once at the front end, it only took about ten minutes.
Hope this helps!!!
Thought I'd add about the same problem I had to fix this past Sunday on my '04 RX Warrior.
If the headlamp 20A fuse has been blowing while riding, you may have experienced the same problem I did; I only had one spare 20A fuse when it blew the second time and had to ride in the middle of our group. I also posted this on John Dee's website.
In the front of the sled:
1. You have to unscrew and remove the toolbox.
2. Unplug the two connectors on the rectifier/regulator assembly [very front of frame]. This makes it easier to wrap the wires with tape. There is a "push pin" release for the connectors; you'll have to feel for them since they face the front of the sled.
3. Look for the headlight wires, they are blue/green and yellow.
If you have the same problem:
4. Find the wire that has the insulation rubbed off and wrap it with electrical tape; it could be both wires. I also wrapped mine with the other wires to have more insulation on the leads.
5. Lift the wiring harnesses up and using a cable tie, tie the harnesses to the upper part of the opening; I found a slot next to the bolt, as you look down, to run the cable tie through. Also, you can cut a 1/4" or 3/8" hose and place it over the sharp edge of the frame before you reinstall the toolbox.
6. Reconnect the plugs, reinstall the toolbox, replace the fuse and you should be good to go.
It took me about three hours to find the problem because I started at the "moving" parts in the steering column end of the wires.
Once at the front end, it only took about ten minutes.
Hope this helps!!!
dexter
TY 4 Stroke Master
thanks for the info... I am actually wondering what my issue really is as I have started the sled and pullled on all of these points trying to duplicate the popped fuse, but couldnt trip the fuse. I was told at my dealer that the relays had some issues, so for $12 I am going to replace that and cross my fingers that it doesnt happen again.
Len Todd
TY 4 Stroke God
Blown fuse = a short. Relays were giving open circuits or in the case of the starter, energized circuits. I would bet that if you are blowing fuses, you have a rubbing wire. And the guys are right. Sometimes you can not even see the tiny hole that allows the conductor to short. They are tellin' you where to look.
i was blowing alot of fuses, sometimes i would go hundreds of miles,no problem! than blow fuse after fuse. i was carring about 20 fuses in my pocket,and replacing them as i went. check your wires again, just the tiniest pin hole, hope you can figure it out!
