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    Main Fuse blows on start

    Sorry, long story.

    Took my bike out for a ride yesterday and had an interesting problem. I stopped for gas and when I hit the start button the started cranked for half a second and then everything shut off, it was completely dead. Checked the fuses and it had blown the Main fuse. I rode another hundred or so miles and then stopped again. And again, same thing, this time it took two fuses.

    I got home and decided it was probably a short somewhere, so I started inspecting all the wiring and switches I could. I did find some cracked wires and a connector that looked like it was falling apart, so I replaced that. After that, the bike seemed to start okay, until after running for about a minute, the main fuse blew again. So today I put a wire where the fuse goes to go to the store to pick up another fuse. I also put the multimeter on the battery to see if it was charging. The meter only read about 12.5 volts at idle, and only crept up to about 12.8 at 4500rpm.

    So I got to the store and went in, when I came up my bike was billowing smoke. It was coming from the regulator rectifier and seemed to be the wires burning. I disconnected the battery as quickly as I could, but the red wire had completely burnt off and was buring other wires. I'm not sure if other wires were burning, or where all the smoke was coming from. So I guess I know I need a new R/R, but does anyone have any ideas if that was the cause initially or if I should be looking for something else. Thanks.

    #2
    Might have been an internal short in the R/R. Best to do now, of course, is to replace the R/R and do some rewiring.

    While the bike is down, go through EVERY connector and make sure they're clean. Not just wipe off clean, but remove the tarnish and get some dielectric grease in there clean.

    After reading through a lot of electrical, I would move towards posplayr's recommendation of the compufire R/R. It is pricey, but I would bet it would be the last R/R and most likely stator set you would ever need.

    Clean up the fuse box connections or replace it entirely as well.

    While rewiring, check the wires and replace accordingly. Z1 carries wires with similar markings that our bikes use, ie., blk/wht, grn/ylw, etc.

    Check the main circuit in this diagram.

    Last edited by Guest; 07-15-2012, 04:54 PM.

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