Main Motorcycle: '08 Speed Triple
Join Date: Apr 2013
Location: Salem, OR
'08 Speed blowing the #6 fuse 20A repeatedly
Hey folks, I'm outta my mind and could use some help.
My bike started blowing fuses early this spring but at the time the only symptom showing was the bike would not start. The #6 (EMS fuse) blows after the kill switch is flipped to start. Ignition key does not do it, only when the kill switch moves and then a dead starter button - no nothing. Battery is great, voltage fine, everything else seems to work okay.
I initially took it to my local Triumph dealer for help with the non-starting, after I'd replaced the battery, thinking maybe it had gone bad - it was less than 2 yrs old and I keep it tendered always. They said they found issues with the way the new battery was sitting (my install) and routing of some cables, they had a bunch of error codes when they hooked up the computer and cleared the codes. They replaced the fuse and it started for them no problem (again, at that time, I hadn't noticed the fuse blowing). I was able to pick it up, start it and get it home thinking it was fine.
I put it on the tender that night, next morning, no start, I couldn't believe it. I didn't check right away but the same problem was happening, fuse #6 blowing.
I was pissed, checked my wiring and found the fuse #6 blown. I also checked the EMS relay and replaced it just in case. Called the dealer, (again, neither they nor myself had narrowed it to the fuse) so they talked me into letting them come pick it up (of course I paid for it), they had it for a while and messed with the battery some more finding some brass jumpers they said I didn't install and they missed the last time, cleared codes, replaced fuse and tried swapping the relay also and to their credit they put in some time riding it around town, pulling over, shutting it off, letting it sit and starting it up again and riding some more. They said they did that about 8 times and never had it NOT start.
I was very glad they put in the extra time and effort so I picked it up, it did start again for me in their parking lot. Got it home (I have about a 40 mile freeway drive home from them), put it on the tender. Next morning, you guessed it - fuse blew again, no start, same problem. I'm wondering if the ride home from the dealer causes enough vibration to make something shake loose or bad connection gone worse? But, if the dealer didn't address that problem, since they were not able to reproduce the blown fuse, why am I able to make it happen (over a dozen times now) in my garage without it starting even once???
I've not bothered to call them nor even consider going there again. I realize they never did get the problem to duplicate so I can't blame them for not seeing what only happened to me. I just can't keep throwing cash (over $600 now) at their over-busy shop to not fix my problem.
SOoooo, I'm trying to fix it myself. I've used my manuals and followed the wiring diagrams. This fuse runs to the EMS relay (which is good, as far as I can tell) then to the ECM and the alternator. I've also replaced my kill switch and starter cluster just in case (hoping it was gonna be the fix and $133 later, it isn't). So I've pulled out the ECM and chased wire looms looking for splits and rubbed casings - no joy. Everything in the battery box area looks fine and is pretty well wrapped up and out of the way. It's been dry all summer and nothing is wet. I can't find any loose connections or really dirty ones either.
Here are my current concerns:
1) I don't know how to check continuity between ends of wires and even if I did (I do have a multimeter) I can't dig through the wire mess deep into the frame of my bike to get both ends of the wires to test - it's a nightmare in there. Getting the ECM out was like pulling a baby out of the top of the mother's stomach - it was a mess.
2) I don't want to keep replacing parts hoping to get lucky. ECM's I hear run around $1100 and I've heard alternators can be rebuilt but still.
3) At this point I have an 11 yr old bike with 35k miles and I'm just worried it's at some point in its life that it may have a serious problem I can't discover.
4) I have a bike all pulled apart that I couldn't ride this whole season and perhaps now it's not worth anything but to part out - which no one really wants bits of anyway because of the age.
5) I've scoured the internet and these forums and can't find ANYONE else with the same problem so I'm worried that portends something awful.
Sorry for the length, it's been a hard season of frustration.