Ignition Fuse Keeps Popping

[Uwood]

Please help if anyone has any idea why ? I have a 2008 Suzuki king quad ltf400f & it keeps blowing my ignishion fuse I have unplugged all the connections in the front besides the ignishion & soon as I turn the key on it pops I I have traced it to orange wire from there & I

Don't have my cci hooked up I tried unplugging voltage reg extra ??? I did take my starter neutral relay apart & it did have broken inside & with that out it still pops it ? Wood that pop it even out ? & a few times I had thought I had it & went to start it & soon as I pulled or used electric start pop ? I am wiped I dunno what to do any help wood be really really really :-)

Thanks

[marioweldinginc]

Check your all your wire harnesses for chaffing. usually a popped fuse is a damaged wire that is touching the frame.

[Uwood]

Yeah that's my next move ! But is there a chance that my starter relay wood do that even dicenected ?

But yeah I am going to half to relay go over my wire harnes ?

[Uwood]

Woo hoo so I don't no why or what but tonight working on it it magicly stopped poping fuse

& ran for first time in 6 weeks :-) I don't no what happend tho all I no is my starter relay is no good as my starter isn't working but it ran from the pull start & the only thing I did els tonight was un hook all the stuff from orange & whit wire ? & slowly hooked em all back & watched as the fuse didn't blo oh & I put the tail light fuse back in as that wire lead there ???? Well tomarow the big test as I put it all back together & try it

:-o all let you no :)wish me luck !!!! Da misery mystery

[CRAZYKIWI]

It only takes 1 wire to earth and the tailight wiring may still cause an issue so make sure that wire isnt shorting? Also they are prone to shorting around the steering where ignition wires can rub as u turn the bars?? Cheers to it going for a long time now!!

[Mudflap64]

Id still be leary that there is a wire rub somewhere. Electrical problems dont normally fix themselves, they tend to hide out until the worst possible time, then rear their ugly heads again.

[Uwood]

Ok so I took it out was good for a hr then poped ! But unlike before it did not pop right away when I put a new on in but riding a few km later ? So after this for 4 fuses I put my spare 30 amp fuse in & made it home no more fuses ? What wood couse this ? I do no it's not good to do & stuff & to all you that no how much of a pain it is to get at it ? Stupid plastic lol anyway if it's a short in the wire wood the 30 amp fuse not of blown ?????

[Mudflap64]

Sounds like a game of chance finding the short. Try pulling the fuse & hooking up a 9 volt dummy light to the dead side of the fuseblock & the frame. Then start jiggling wires, when the light keeps flickering on & off youre getting close. Definately sounds like a chaffed wire to me. You unfortunately will probably need to be taking off some of the plastics. Focus on the steering shaft area,dash and any othe places moving parts could rub thru wiring. Especially look behind tie straps where the harness is attatched to a frame member or metal brackets. Good luck. Youll be ecstatic when you find a bare wire. :-) Also, make sure the ignition switch itself isnt bad & shorting out internally. ( unplug it while doing the test.) Do you have a heavy keychain hanging off the key?, just a thought.

Edited August 19, 2013 by Mudflap64
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