ignition fuse keeps blowing

[TrailWhisperer!85]

so the ignition fuse on my bike blows the second the main switch is on, but only if the kill switch is in the run position. if it's off, fuse stays intact. this started mid-ride—engine cut out and wouldn't restart. smelled something nasty from the battery, so i swapped it out and started troubleshooting. disconnected stuff like the cdi box, coil, starter relay—still blowing. ohm-tested the stator pick-up coil, and it's in spec. even cut a wire that didn't show in the diagram. fuse still pops. anyone seen this before? i'm all ears before i fork over cash for a new cdi box.

 

[CharmlessMan]

Any rats or other kinds of evil rodents there? I suspect it's them that chewing an unseen spot, although it can be a wiring problem too

 

[skipper121]

so the ignition fuse on my bike blows the second the main switch is on, but only if the kill switch is in the run position. if it's off, fuse stays intact. this started mid-ride—engine cut out and wouldn't restart. smelled something nasty from the battery, so i swapped it out and started troubleshooting. disconnected stuff like the cdi box, coil, starter relay—still blowing. ohm-tested the stator pick-up coil, and it's in spec. even cut a wire that didn't show in the diagram. fuse still pops. anyone seen this before? i'm all ears before i fork over cash for a new cdi box.

Ugh, this is annoying. The switch might be acting up inside, check the wires for any damage. If you can't find anything wrong, check this with a mechanic. they will know where to look.

 

[Auld.lang.syne]

so the ignition fuse on my bike blows the second the main switch is on, but only if the kill switch is in the run position. if it's off, fuse stays intact. this started mid-ride—engine cut out and wouldn't restart. smelled something nasty from the battery, so i swapped it out and started troubleshooting. disconnected stuff like the cdi box, coil, starter relay—still blowing. ohm-tested the stator pick-up coil, and it's in spec. even cut a wire that didn't show in the diagram. fuse still pops. anyone seen this before? i'm all ears before i fork over cash for a new cdi box.

If the fuse only blows with the kill switch in "run," it's likely a short in that part of the circuit, so in your shoes I'd check the kill switch wiring, especially inside the bars and look for rubbed or melted wires near the frame or tank. CDI could be bad, but rule out wiring first before spending cash

 

[common.person]

so the ignition fuse on my bike blows the second the main switch is on, but only if the kill switch is in the run position. if it's off, fuse stays intact. this started mid-ride—engine cut out and wouldn't restart. smelled something nasty from the battery, so i swapped it out and started troubleshooting. disconnected stuff like the cdi box, coil, starter relay—still blowing. ohm-tested the stator pick-up coil, and it's in spec. even cut a wire that didn't show in the diagram. fuse still pops. anyone seen this before? i'm all ears before i fork over cash for a new cdi box.

It's a short for sure but we just don't know where. Possible that a wire rubbed through when the kill switch is live. Try checking the wiring harness around the handlebar and frame for any damage before buying parts that might not even work unless the full issue is resolved.