SuzukiSavage.com - need help with popping fuses

jhnzeigler YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25	need help with popping fuses 10/09/11 at 15:30:04 Ok...So I need a little help...Does anyone know of an easy way to hook up a rear light? Im still having a problem with the fuses popping with the front break lever...
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: need help with popping fuses Reply #1 - 10/09/11 at 15:42:07 so when does it pop?
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verslagen1

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Re: need help with popping fuses
Reply #2 - 10/09/11 at 15:57:15

Both the front brake switch and the rear brake switch get power from the ig switch from separate sources.

Both the wires from the switches are tied together somewhere and go to the brake light.

If it were the power wire to the switches you'd have trouble immediately when you turned on the ig.

If it were the brake light wire, you'd have trouble when either switch was turned on.

Seems to me that either you have a cut wire grounded out, someones reversed the wires at the connector, or a bad switch.

what year?

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jhnzeigler YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25	Re: need help with popping fuses Reply #3 - 10/09/11 at 18:01:42 the bike is an 86...The fuse pops about 2 to 3 seconds after the front break is pulled and held...oh and instead of getting brighter it gets dimmer...Im was thinking the wires were backward but after switching the same thing happened...Im really confused and this is the last thing I need for my bike to be done. Ziggy
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: need help with popping fuses Reply #4 - 10/09/11 at 18:50:55 I think the contacts have become misaligned or broken and is shorting against the handle. this brake light switch isn't the greatest.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: need help with popping fuses Reply #5 - 10/09/11 at 19:05:39 Based on the time that passes, Id lean toward Versy's idea,, See if you can bypass the switch & make the light come on & it not blow the fuse.
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Routy Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2280 Winston Oregon Gender:	Re: need help with popping fuses Reply #6 - 10/10/11 at 07:27:46 yes, use process of eliminization
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AlphaBarney

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Re: need help with popping fuses
Reply #7 - 10/12/11 at 18:37:02

Are you trying to install an aftermarket with 2 wires from the new light? I just installed one on my bike tonight and originally had the same problem. Popping fuses like crazy.
After taking apart the stock brake assembly I noticed that the black wire with the white stripe was hooked to the bulb housing and the brown wire and white wire with the black stripe were hooked up to the bulb itself. Once I found the connection to the bulb housing on the aftermarket (had 2 wires, one red, one black) and hooked it up like the stock...no more popped fuses. I originally hooked the two lead wires up backwards so I got a really bright tail light with no brake function. Switched the two and TADA...worked perfectly with fuses in tact.

Not sure if this helps or is on the ballpark, just sharing my experience.

In short:
Black with white stripe -- bulb housing (ground?)
Brown wire -- red or black
White with black stripe -- red or black

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"Betty"-'05 S40

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jhnzeigler YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25	Re: need help with popping fuses Reply #8 - 10/15/11 at 09:39:37 So I just thought of this and It might be the answer to my problems if it is true...Is the wiring harness supposed to be grounded to the frame? Is there a seperate way to ground the harness itself other then the ground wire from the battery?
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jhnzeigler

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Re: need help with popping fuses
Reply #9 - 10/16/11 at 19:51:35

Ok I figured it out and got the brake light working...thank you for all the imput.

Now I am really close to getting the bike finished...Will be posting pictures soon...I think I have done so pretty cool upgrades/custom work on the controls...or at least I havent seen it done before on the Savage.

I have successfully change the controls to 7/8" bars and upgraded the light/horn/turn signal switch, used sport bike levers and changed the starter kill switch to a Honda RC51 control unit and independant throttle housing...

Fired the bike up tonight and all is working well...
Pics soon to come and first ride even sooner...
Ziggy

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: need help with popping fuses Reply #10 - 10/16/11 at 19:59:33 jhnzeigler wrote on 10/16/11 at 19:51:35: Ok I figured it out and got the brake light working...thank you for all the imput. So? what was it?
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jhnzeigler YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25	Re: need help with popping fuses Reply #11 - 10/16/11 at 20:07:17 with the conversion that I did the wires got all mixed up. I went back through the wiring and I had two power inputs (orange adn white wires) going into the same connection...this was feeding too much power and popping the fuses...So it was an easy fix with a huge headache lol Ziggy
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: need help with popping fuses Reply #12 - 10/16/11 at 20:15:17 One of those wires was in the ground position,, I told ya to look for that.
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jhnzeigler YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25	Re: need help with popping fuses Reply #13 - 10/17/11 at 08:03:14 You sure did and thank you
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AlphaBarney Full Member Offline Were you born to resist, or be abused? Posts: 121 Raleigh, NC Gender:	Re: need help with popping fuses Reply #14 - 10/17/11 at 14:37:18 Nicely done. Can't wait to see the pics. I'd love to replace the hand controls with something not so cheap looking; maybe I can steal some ideas.
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