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Message started by scooter13 on 05/10/11 at 15:49:50

Title: main fuse issue
Post by scooter13 on 05/10/11 at 15:49:50

I have a 2005 savage. Ran fine yesterday, now when I turn the key the main fuse blows. KIll switch is off, blows. disconnet the reg/rec, blows. Cannot find a short or crimped wire anywhere. Any Ideas?
Thanks.

Title: Re: main fuse issue
Post by justin_o_guy2 on 05/10/11 at 16:07:33

Gonna have to disconnect stuff & then hit the key.. see what is he last thing plugged in when it starts poppin fuses. If you ont have a Volt /Ohm meter,, you gonna need one,, & a test lite. & a Miller Lite..

Title: Re: main fuse issue
Post by Garyt on 05/10/11 at 17:16:44

Replace the fuse with a 12volt light bulb turn the key on and start moving stuff. When the light goes out you have found the short. Have fun.
Gary

Title: Re: main fuse issue
Post by scooter13 on 05/10/11 at 19:47:49

as soon as i turn the key to the on position the fuse pops. won't this affect the bulb?

Title: Re: main fuse issue
Post by verslagen1 on 05/10/11 at 20:10:18

2522393F22297C7E4D0 wrote:

as soon as i turn the key to the on position the fuse pops. won't this affect the bulb?

this threw me at 1st too, but think about, the bulb is made to run on 12 volts and will keep the current down so the short won't burn up the bike.

Title: Re: main fuse issue
Post by scooter13 on 05/10/11 at 20:20:12

makes sense, now any info on the best way to harness the light to the main fuse seat?
thanks

Title: Re: main fuse issue
Post by justin_o_guy2 on 05/10/11 at 20:24:48

Solder leads onto a bulb, Id use an 1156, & put spade connectors on them,, cut to fit

Title: Re: main fuse issue
Post by scooter13 on 05/10/11 at 20:40:09

Thanks guys, after spending the greater part of 2 days testing parts and looking for a bad ground, I was not looking forward to another. Now I can't wait to wade through it again with a new toy.
Will post after.
Thanks again.

Title: Re: main fuse issue
Post by scooter13 on 05/11/11 at 18:36:12

As suggested, Light was hooked up, key turned on and the light went out when the Red secondary wire to the starter relay was disconnected. Too dark now, have to trace the other end tomorrow. It is a single red wire with gray dots. Any Idea where this is going to lead? It is tucked inside the harness that runs forward under the tank.

Title: Re: main fuse issue
Post by WD on 05/11/11 at 19:15:19

Open up your switch boxes. Mine is always breaking/pinching wires where they go in. It finally fried the starter relay. Solenoid is fine, relay is shot. Seat and gas tank tend to pinch wires as well.

And mine did the same as yours when a spider made her nest/egg case in the starter button housing.

Title: Re: main fuse issue
Post by scooter13 on 05/13/11 at 10:35:04

OK, after doing the test, the bulb only went out when the red secondary wire coming from the starter relay to the main fuse was disconnected. How do I test my ignition switch?

Title: Re: main fuse issue
Post by OE on 05/13/11 at 18:50:53

I have a Clymer manual that goes up through 2004 so what I'm looking at may not apply to your bike. The wiring diagram doesn't show a wire like you described going to the starter relay. (red with grey dots) Also, this diagram shows two fuses. The main goes to the ignition switch and the other one goes to the decompression controller. I can't distinguish the colors either. Red and orange look alike to me. The wire going to the decompression controller could be red and grey or orange and wihite or orange and grey. Just can't tell.

I don't think there's much chance it's the ignition switch either because it's just supplying power to something else that's shorted.

Sorry I don't have a good answer for you. I'm just shooting in the dark.

Title: Re: main fuse issue
Post by scooter13 on 05/13/11 at 19:27:42

Thanks for all the suggestions. We traced it to the front turn signals. With the front turn signals disconnnected from the harness, both sides spiked the meter. The screws that hold the lights to the frame had poked a hole in the wires on both turn signals and was making contact with the frame.
what a headache.

Title: Re: main fuse issue
Post by justin_o_guy2 on 05/13/11 at 21:19:02

Bummer deal, but if you found that, you are doin good.

Title: Re: main fuse issue
Post by scooter13 on 05/13/11 at 21:22:55

Thanks again Justin, the bulb led the way.