Main Fuse Kept Blown

What a day. I have spent hours on my 2003 Honda Silverwing 600 today figuring out what is causing the problem.
I have posted this earlier but decided to create a new post now that it might be an electric issue instead of a fuel issue.

It happened while I rode my bike, the engine suddenly stops running. I tried to restart it but it acts like it is not getting any gas which I was under the impression that the fuel pump or fuel-related issue may not be working. Then the bike no longer had power.

I replaced the battery under warranty, new spark plugs installed, double-check with side fuses (looks fine). Then I finally checked with the main fuse. Good enough, the 30A fuse has been blown. Okay, I got a new fuse installed, but when I turn the switch to "ON", nothing. No power, no light. I checked with the main fuse again and it did blow! I replaced another one and try again. Yeah, it did get blow again.

Now I am stuck with what to do. What does this mean? What is the solution to fix this?

At this point having the electrical diagram for your bike would be in your best interest. You could start at the fuse and trace wires looking for the obvious short. Long distance electrical problems are not easy, a lot of variables. One thing that you said caught my eye, none of the other fuses are blown, so you put in a new fuse and try to start the bike and it blows the fuse? or will it run a bit and blow, the 1st would indicate to me a dead short in the starting circuit.

oldwingguy wrote:

One thing that you said caught my eye, none of the other fuses are blown, so you put in a new fuse and try to start the bike and it blows the fuse? or will it run a bit and blow, the 1st would indicate to me a dead short in the starting circuit.

None of other fuses has blown. Only the 30A in the main fuse. Every time I TURN THE KEY TO "ON" (not start), the main fuse blow. Twice. When I turn the key to "ON" there was power. No light on the instrument panel. Just nothing, yet it still blow the main fuse.

I am no electronic expert. Could be short. Could be a bad stator. I do not have a cigarette lighter installed. No third-party stuff to draw power from the battery. Which is strange.

Stator, or wires leading to it. The good of the bad is no added wires. I had a stator go bad in my GL1200 it never blew a fuse just drained the battery while running.

Guess I will have the bike tow to shop and let someone do this. No youtube or even pictorial tutorial on stator replacement.

I would look for a shorted wire first before going to a shop, who knows you may get lucky and find the problem. From what I read the S'Wing doesn't seem to have the problem the 1200 had which was by the way an external wire / connector problem. Good luck.

I don't even know what shorted wire looks like or where to look for it.

Burnt, melted plastic coverings. Where to look, that where the manual comes in handy.

R/H side, a quick look at my manual shows a connector behind the body work, once that is removed the connector is easy to see, a plug and play. You could take the connector apart to check for corrosion and or burnt wires. U Tube may be your friend too.

1-I would start by disconecting the starter.... If it keep on burning the main fuse,
2-try to change switch if you have a friend owner in your area with a SW.
Keep on you will find it for sure ....
3- unplug the kill switch !.......
4- follow the main wiring and look for melted plastic around the wires...
After all that I give up... because I'm sure you found it....
lets go keep on , be positive ... Good luck !
Michel

I wouldn't worry about the stator or the regulator, those just affect battery charging, and don't play any part when you just switch on the ignition.

The main fuse feeds directly through the starter relay to the starter motor,. All of the other circuits (lights/indicators/starter button/fan etc) feed through their own subsequent fuses which are generally lower amperage so if the short lies with them, those smaller fuses blow, not the main fuse. You can test whether any of those circuits are faulty by pulling all of their fuses, then add one at a time and repeat the power on test and see if any blow.

Most likely (in my mind at least) the fault lies in/around the main fuse and starter solenoid, and I would be looking for charring around that area and then along the red wire that leads to the ignition switch and the red/black wire beyond that back to the fuse box.

Terry Smith wrote:

I wouldn't worry about the stator or the regulator, those just affect battery charging, and don't play any part when you just switch on the ignition.

Okay.

Quote :

The main fuse feeds directly through the starter relay to the starter motor,. All of the other circuits (lights/indicators/starter button/fan etc) feed through their own subsequent fuses which are generally lower amperage so if the short lies with them, those smaller fuses blow, not the main fuse.

There are no blown subsequent fuses in two smaller fuses box. Only the main fuse (30A).

Quote :

You can test whether any of those circuits are faulty by pulling all of their fuses, then add one at a time and repeat the power on test and see if any blow.

Okay, so you’re suggesting that I take all subsequent fuses out of two smaller fuse boxes, righ and test with one of them in at time to see if it cause main fuse to blow?

Quote :

Most likely (in my mind at least) the fault lies in/around the main fuse and starter solenoid, and I would be looking for charring around that area and then along the red wire that leads to the ignition switch and the red/black wire beyond that back to the fuse box.

If the main fuse 30A fuse blow without any blown subsequent fuse. The problem is bad starter, right?

Thanks for your patience answer my questions.

Okay, guys.

I felt like a moron. The reason why my main fuse blow is because I have the battery connected wrong.

thanks for your help.

I was all set to write up a reply to your question!! Fantastic news that you solved your own problem.

Terry Smith wrote:

I was all set to write up a reply to your question!! Fantastic news that you solved your own problem.

Thank you.