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Ignition fuse (r/w wires) gets hot and blows, new problem

Discussion in 'The Garage' started by Godric, Aug 18, 2019.

  1. Godric

    Godric XS650 Member

    Hey yall, I almost had this bike (81 xs stock) ready for the road, but recently it's been blowing the ignition fuse. On my numerous test rides up until recently it hasn't been an issue, but now it's eating through fuses and today I couldn't even get it started. The ignition fuse gets wicked hot and blows, and the neutral light is weak with the fuse in. I really hate electrical stuff but I figure I gotta learn if I wanna ride. Could this be due to a short? The igniton is a 10A, which it's eaten through 3 of so far, I even tried a 20 and it melted the cap off the fuse. Like I said it just started out of nowhere. I might have something cross wired in the taillight area above the rear fender from messing around with it, but even after I disconnected that section it's still having this problem. It's a one kick start bike and I couldn't get it fired today. Maybe it's time to inest in a new harness?
  2. gggGary

    gggGary On the road of life I'm a speed bump. XS650.com Supporter Top Contributor

    You have the right idea, unplug one thing at a time till the fuse quits blowing. The last thing unplugged will have the short.
    I might shortcut and carefully check where the wire bundles go through the rubber grommets in the back of the headlight bucket. A failed grommet can let a wire get cut by the bucket edge. In general the bucket is a popular place for electrical problems.
    I just blew an ignition fuse today, my lowered seat pan hit the fuse holder. :redface:
    GLJ and peanut like this.
  3. Godric

    Godric XS650 Member

    Woke up this morning and went right to checking wires, had it figured out in 5 minutes. The solenoid was grounding out on the frame, thanks yall!
    Ozboy and gggGary like this.

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