Main fuse kept blowing

I was out riding friday all day and she road good, stopped off at a car show for a bit, when i got back to the Z1, there was a few people looking at it. I commented on how easy she started and how great she runs, well as soon as i put the key in the ignition i turned it on and popped the main fuse. Put another one in and made it home ok. Went out today and found ot that the end ok my ignition switch was melted abit at the end. It was like this when i put it on about 3 weeks ago in a pinch. Does anyone think this was my problem? Here is a pic of the switch itself

If that is actually brass showing in the picture there is a definite chance it could be.
And, isn't it amazing how things like that happen when there is a crowd around???? :laugh: :laugh: :laugh:
I guess that's Murphy's law at work again,
Ride safe

Looks like a dead short. Which btw will blow a fuse everytime.:woohoo: Glad you made it home. I had a pinched wire in the headlight bucket one time. Use to give me fits until I found it.

yea i thought that might be the bugger. Im ordering a new one from jeff at z1.

I had a similar problem on a group ride. That area in your pic that is burned would touch my headlight shell and blow the main fuse, 3 or 4 times during the ride when I turned the handle bars a certain distance. Some electrical tape got me going again.

well good news i got the z1 running. I got the ignition switch today, i rode it for about 15 miles with no problems. In the 2 weeks the bike was down i put the stock 4 into 4 exhaust back on, and mad do those 4 pipes sound sweet while im running down the road.

AH i spoke to damn soon. I popped another fuse tonight. I think there has to be as hort under my tank some were. Im stumped, i was sitting in traffic and waiting for a freight train to pass, the bike ran great all day. The light turned green, i turned the corner and halfway down the street it just shut off. I wiggled a few wires and it fired right back up and got me home. Any ideas?????????

Post edited by: oldkaws4ever, at: 2007/08/16 23:35

im taking a complete guess here, but is there any way that the ring termonals on my dyna coils could be touching the frame causing it to pop the fuse?

i probally should have mentioned this earlier:whistle: , but the fuse only blows when i flip the kill switch to the run position. The switch is brand new from Z1 enterprises.

1) Kill Switch:

On my bike the Kill switch only feeds or disconnects the coil circuit.

Move the switch to the Kill position, remove +12 Vdc lead to both coils and use a meter to check for shorts between each lead and ground. If you get a reading of around zero ohms then you may have nicked one of your wires while installing the new switch gear.

In my case, I had an impossible to see short inside the switch gear such that I ended up putting shrink tubing on all leads... no more short!


2) Coil +12 Vdc Shorting To Frame:

I did not think this was a problem with the original coils. However, if you have Dyna replacement coils this is a very real possability or even probability. I covered the adjacent mounting post with shrink tubing.

A member mentioned that if it gets wet the shrink tubing may conduct. So, just when I thought I had seen it all, on another post a newer member told me about Liquid Electrical Tape that you apply directly to the +12 Vdc bolt... spray or dip formulas no less. Sounds like the ultimate solution to me. I'll be checking out my local big-box hardware store for that one real soon!

Just a last thought, I would not expect the fuse to blow just because of arching to the frame so let us know what you find... for sure!

Best of success.

Post edited by: bill_wilcox100, at: 2007/08/17 08:25

Post edited by: bill_wilcox100, at: 2007/08/17 08:44

Post edited by: bill_wilcox100, at: 2007/08/17 08:48

ok good news, i think im 100% sure in saying i found my short. The mounting post was touching the power supply to the coils. I disconected power to the left coils and turned ignition switch and kill witch on and bam the fuse popped. I disconnected the power to the right side coils and turned the key and kill swith on and all light's were good and no popped fuses. So for a temp fix i removed the metal mounting post bolted the coil back up. Fired it up and she ran good. Went for about a mile ride with zero problems. I hope that was my problem

Way to go!