SuzukiSavage.com - Blowing Fuses Left and Right

Goirad

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Blowing Fuses Left and Right
02/26/15 at 11:45:08

Here is the situation so far:
I have a 2001 savage with 7k miles on it, and a brand new battery that is 2 weeks old, it worked perfectly fine for the last 2 weeks.
Here's what I've gotten so far:

- Battery reads 12.6 volts
- Both 20 Amp fuses are fine
- The bike is in neutral, on, and all the appropriate indicator lights are bright and working
- I hold in the clutch and press the ignition switch
- I watch the neutral light dim while I have the ignition switch pressed, there's no sign of noise or movement from anything
- I then watch the fuse labeled relay evaporate before my very eyes
- I've repeated this procedure twice, and it's the exact same thing both times.

Anyone have any ideas?

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Blowing Fuses Left and Right Reply #1 - 02/26/15 at 11:53:16 Disconnect the cable between the starter and the relay....so that the starter is not being energized when you push the starter button. The relay should energize and remain calm without blowing any fuses. If the fuse doesn't blow....then maybe something is wacky with the starter.
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Goirad YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Blowing Fuses Left and Right Reply #2 - 02/26/15 at 12:47:46 Thanks for the quick reply Dave. I disconnected the starter motor and the fuse still blew, which should mean that there is something wrong with the rest of the starter system. Any other ideas to try?
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Blowing Fuses Left and Right Reply #3 - 02/26/15 at 12:57:08 I can only suggest that you keep unplugging things until you find out what is blowing the fuse. Here is a link to the wiring diagrams in the technical section. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1294779818
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Trippah Serious Thumper Offline I ride, therefore I am. Posts: 2517 central Mass Gender:	Re: Blowing Fuses Left and Right Reply #4 - 02/26/15 at 13:10:51 Just to embarrass myself, check out the battery, connections and wires (routing)that might have since melted together. I always check what I just "Fixed" first and that usually where I find the problem.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Blowing Fuses Left and Right Reply #5 - 02/26/15 at 13:34:01 Trippah: You might be on to something.....something might have gotten crossed up when the battery was installed. Those wires down the front of the battery box are pretty well jammed together - it would be easy to pinch something and short it out in that location.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Blowing Fuses Left and Right Reply #6 - 02/26/15 at 16:45:29 If you took the tank off, whatever you've done, go back and look.
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Gary_in_NJ

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Re: Blowing Fuses Left and Right
Reply #7 - 02/27/15 at 05:16:17

Dave wrote on 02/26/15 at 13:34:01:

Trippah:

You might be on to something.....something might have gotten crossed up when the battery was installed. Those wires down the front of the battery box are pretty well jammed together - it would be easy to pinch something and short it out in that location.

+1 That's where I'd start

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Goirad YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Blowing Fuses Left and Right Reply #8 - 02/27/15 at 06:54:16 Update: I checked all those wires by the battery and they all seem to be intact. Next up I'm going to take the wiring diagrams and erase everything that depends on the main fuse, and start eliminating whatever is left.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Blowing Fuses Left and Right Reply #9 - 02/27/15 at 07:26:57 Isolate the starter solenoid from the system. That can certainly blow a main fuse if shorted.
Back to top	A life-time student of motorcycling. LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Blowing Fuses Left and Right Reply #10 - 02/27/15 at 07:43:45 I'd pull the wire from the start button that goes to the solenoid and check voltage on it when you push the button. If it blows, you're onto it.
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Goirad

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Re: Blowing Fuses Left and Right
Reply #11 - 02/27/15 at 08:40:22

Great news everyone!
The wire bundle coming down from the right hand controls was resting too tight against the metal flanges that hold the top of the engine. The plastic stood no chance against the sharp edge and there was the short. A little electric tape and an old pen grip for reinforcement should solve the problem. After separating the short the engine turned right over.

Thanks everyone for all your help

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Blowing Fuses Left and Right Reply #12 - 02/27/15 at 08:42:07 Ooooh! I love happy endings!
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Art Webb Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3007 columbus, Texas Gender:	Re: Blowing Fuses Left and Right Reply #13 - 02/27/15 at 09:41:04 Yay!
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28660 Tucson Az Gender:	Re: Blowing Fuses Left and Right Reply #14 - 02/27/15 at 11:14:48 Both my fuses are on the right... ... ... Congratulations,.. (I've been holding that remark 'till you got this thing fixed)... Finally free to let it out... ...
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