Triumphrat

TexasTBird · 10-21-2009, 12:47 AM

I rode 30 miles in driving rain on my 2003 TBS coming home from work. The holes in the airbox were sucking so much water that it was running rough but kept going. Within a few hundred yards of home it died and would not try to restart although all lights were working. After days of checking and cleaning connections and testing various switches, the starter relay, etc., I finally discovered the inline fuse, which was blown. I have replaced it several times and it continues to blow, usually after running well enough in the shop to trick me into thinking I had solved the problem. Pushing the bike a mile and a half, mostly uphill, to get back home may be good exercise, but I have had enough. I have studied previous posts and found one (11-14-2007) where JimmyJ900 said "Don't be too worried if the fuse is blown --unless the replacement blows immediately". The fuse does not blow "immediately", but I am getting worried. Is there a common solution to this problem?

Thanks for your input. Here is a cyber Scotch for your trouble.

TexasTBird

jimmyj900 · 10-21-2009, 09:41 PM

The inline fuse goes to the run/kill switch and ignition system, so it runs up to the headlight through a connector, to the right grip, back through the headlight connector and then to the coils.

The odds are that the igniter and coils are OK and it's most likely an intermittant short caused by damaged insulation so you're going to have to run through the wiring and look for chafed insulation that's shorting to ground and blowing the fuse.

The most likely locations are at the wire entry port in the headlight and at the wire hold-down arms inside the headlight.

Good luck! Chasing nicked insulation can be a PITA!

JJ

TexasTBird · 10-22-2009, 11:13 PM

The most likely locations are at the wire entry port in the headlight and at the wire hold-down arms inside the headlight.

JJ[/QUOTE]

Blessings on you, JJ. I came in from the shop where I am working on tracing the wiring, armed with my multimeter and the wiring diagram, to find your message. I have the headlight shell open and will concentrate on the points you mention first. I have been drilling a lot of dry wells and am looking forward to striking oil. The weather will be beautiful for riding tomorrow and I hope to be in it. Hope you are, whether I make it or not.

TexasTBird

TexasTBird · 10-23-2009, 02:09 AM

I found a wire with nicked insulation under the wire hold-down arms inside the headlight, bandaged it with electrical tape, put all the pieces back together and just got back from the longest test drive in days. I will ride to work tomorrow. Thanks again, JimmyJ!

TexasTBird