Thread: Fuse at battery blows

Ok I am stumped. On my Z50 K1 the battery fuse blows as soon as I plug the battery to the harness. The wife was riding it the other day and no issues. We went on a 8 mile ride and the lights and all worked fine. I went to start it yesterday and the battery was dead. So I charged the battery but now when I plug it in the fuse blows. I put in a new fuse and back on the charger and the fuse dosent blow. What the heck I am doing wrong or what am I missing ?? I have gone through 5 fuses trying to figure it out !!!

Mike

Originally Posted by maugust24

Ok I am stumped. On my Z50 K1 the battery fuse blows as soon as I plug the battery to the harness. The wife was riding it the other day and no issues. We went on a 8 mile ride and the lights and all worked fine. I went to start it yesterday and the battery was dead. So I charged the battery but now when I plug it in the fuse blows. I put in a new fuse and back on the charger and the fuse dosent blow. What the heck I am doing wrong or what am I missing ?? I have gone through 5 fuses trying to figure it out !!!

Mike

Time to do a little troubleshooting.I would start by removing bulbs and try again.Then start tracing wires looking for one grounding out on frame,etc,,,Try disconnecting all lights and see if it still blows fuses.Something is fried or going to ground.
Process of elimination.
LOL,
Dennis

Thanks Dennis I will give that a try. Everything was brand new a year ago when I restored it from the key switch, taillight, wire harness and cables and battery. Basically all electrics were replaced. The only thing I reused was the rectifier. Could that be bad??

If it were me I'd start with what I consider the obvious - the battery. It's the last thing "changed". Or charged if you prefer. Could be possible something shorted in/with it...

Ok I am still stumped, Dennis I did what you said and all the light bulbs were good. I checked the battery voltage both with the fuse and without and it puts out 6.2 volts. I put a new fuse in and used jumper wires to a 12 volt bulb just to see if it would blow and it didnt. So I hooked it up to the bike and it popped. Just for testing I put a 20 amp fuse in. I disconnected the rectifer and hooked the battery up and the brake light/ tail light worked for a few seconds and then quit. The fuse didnt blow but it was blazing hot. I also checked the bulb and it wasnt blown so I dont know why it quit. I am confused. Anyone have any other ideas?? Could the stator be shorting out?? The wire harness is new and I looked it over and it looks to be ok.

HELP !!

I'm stumped.

I was thinking battery since I thought maybe something was/is amiss somewhere in the four way(?) connector from battery to harness.

I meant to remove the bulbs completely and then see if fuse still blows.I would even disconnect lights completey and check to see if it clears short.I wouldn't try useing larger fuses because you are risking melting your wiring harness.
Process of elimination.........
May be your ignition switch,wiring harness,etc...you are going to have to just eliminate each item til you can pinpoint short.
Try unplugging your stator and see if fuse still blows.

Dennis, yes thats what I did I just didnt explain that well in the post. And I started to do exactly what you just said. It just got to late to finish. I am going to unplug eveything and plug one thing at a time in and see where it gets me. Thanks for the advise and help. I will post my findings. I hope it is not the harness or the switch as they were both brand new and not even a year old yet.

Mike

Ok finally got it dailed in. I unplugged everything from the wire harness and then started plugging in one wire at a time. Found a shorted out rectifier on the red wire side. The second I plugged that wire in things got hot quick. Burned my damn finger on the hot fuse. Just ordered new rectifier so I will get that in and should be good to go.

Mike

Yesterday you couldn't even spell electrician,now u- r- one !
Glad you found it.