stuck at work while my bike keeps blowing fuses

[Anonymous]

Hey everyone,

Hopefully someone can give me a few pointers. My bike has been fine for the past week (except for a bad stator which Im replacing this weekend). I started it up to go for lunch and my Main 15 amp fuse keeps blowing only while using the electric starter. (I can turn the key on and it's fine, i get power but as soon as i go to start up it blows). Anything I should look at /trace that may be of help?

81 suzuki
gs550t


thanks,

john

[redliner1973]

Sounds like very corroded/bad/shorted wire or connecter assy. aside, of course from the starter itself traking a dump on you. Push start it and limp home, if it will let you....

[earlfor]

Re: stuck at work while my bike keeps blowing fuses

Most likely is the starter solenoid (usually located under the left side cover)
shorting out. You can go to Home Depot and buy a new solenoid for a lawn tractor for under $10. It will work just fine. Been there done that. :-)
If it still blows fuses, I would expect it to be the starter brushes. I would also pop the back off of the fuse block and check the internal connections for corrosion and check the battery ground to frame connection for corrosion.

Earl

Hey everyone,

Hopefully someone can give me a few pointers. My bike has been fine for the past week (except for a bad stator which Im replacing this weekend). I started it up to go for lunch and my Main 15 amp fuse keeps blowing only while using the electric starter. (I can turn the key on and it's fine, i get power but as soon as i go to start up it blows). Anything I should look at /trace that may be of help?

81 suzuki
gs550t


thanks,

john

[Planecrazy]

As a quick fix I second the corroded (or even loose) wire idea ... Check all your main cables to make sure they're tight ... a loose one (Pos battery/Ground Cable, etc.) can cause unusual problems that blows fuses.

Good Luck!
Steve 8)

[Anonymous]

ok. i've checked the wires the best that i could, check the fuse assemblies which seem great. I'll start looking at the starter relay and starter motor. the interesteing thing is that it didnt really want to start when the bike was pushed which was not a problem in the past. If the starter motor is fried but still connected can it cause electrical problems during a push start? can i just disconnect the starter and push start as a test?

[earlfor]

Its conceivable that if the solenoid is shorted, it could be leaking low level current. In any event, yes you can disconnect the power supply lead to the starter. That cant cause any harm.

Earl

ok. i've checked the wires the best that i could, check the fuse assemblies which seem great. I'll start looking at the starter relay and starter motor. the interesteing thing is that it didnt really want to start when the bike was pushed which was not a problem in the past. If the starter motor is fried but still connected can it cause electrical problems during a push start? can i just disconnect the starter and push start as a test?

[SqDancerLynn1]

If the stator/reg are bad it could cause your problem. DIsconnect the reg & stator wires and try it

[Anonymous]

ok. interesting. I disconnected the starter and attempted push start-no luck. I then disconnected regualtor and stator (which are defective at least the stator is) , then charged battery and attempted electric start. It attempted to start and sounded good but did not start but did not blow the main fuse everytime like when the regulator/stator was connected.

an interesting thing happens when my friend pushes and i pop it in first. it sounds like the engine is running but extremely quiet and slow , im seriosuly pushing the bike 2 mph and it sounds like the engines doing something but im not quite sure what.

starter now sounds strong, full charge, full tank. nothing else has changed. maybe something with the ignition system? maybe it's putting out a really weak spark?

[SqDancerLynn1]

If the reg was bad it could spike 18 volts to the ign and kill it. Pull a spark plug and check for spark See if maybe the plugs are fouled

[Anonymous]

Hi, I had the same problem with my 650. It turned out to be the R/R. What I was told from Electrex is the R/R grounds ( or is it shunt?) the stator field from the 3 wires from the stator when it dosen't need a charge.. If one dosen't ground, it surges the system on the one line & blows the fuse. Told was common. $112.50 to my door on replacement. I replaced the R/R & no fuses blew. Dave

[Anonymous]

Ok, the stator AND regulator are disconnected and the starter still sounds good. I pulled out 2 plugs and it didn't look good. on top of that I checked the spark.....and there was none whille running the starter.

so can i get to my ignition units easily? did i test the plugs right? (i pulled them out and touched the plug body (not the tip) to the engine and attempted to start. What a bummer, and i just got my electrex stator and regulator , napoleon mirrors and boots today!

thanks for the help

[Anonymous]

thanks for the help everyone,

I was getting down since it's been raining here in california for 3 days straight. i was leaving work on Tue and decided to look at my bike one last time in the pouring rain. i noticed......a burnt out ground wire coming from the ignitor unit... today i spliced it back together and......the sweet sound of the engine was back! i think since it kept blowing fuses with the regulator and stator hooked up it was most likely those components (i know my stator is bad). got a new electrex setup waiting to be installed.

thanks again

John