Author Topic: Main fuse keeps blowing  (Read 25998 times)

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Offline TwoTired

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Re: Help! I keep blowing my main fuse....
« Reply #25 on: May 25, 2006, 09:53:48 AM »
What model bike?
What year bike?
What is your fuse value?
Is it a stock fuse value?
Is it the stock fuse type?
Is it the stock fuse holder?
Is your whole electrical system stock?
Are all your electrical components stock?
Have you ever cleaned any of the electrical connectors on the bike?
Have you ever cleaned the fuse holder contacts on the bike?
Does the fuse feel hot to touch during operation?
Did you just say ouch?
Have you searched for the topic "WTF Fusebox" ?
Do you need six more questions?

Lloyd... (SOHC4 #11 Original Mail List)
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Offline Caferacernoc

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Re: Help! I keep blowing my main fuse....
« Reply #26 on: May 25, 2006, 11:43:19 AM »
What model bike?     CB750
What year bike?      1972
What is your fuse value?      15amp
Is it a stock fuse value?      Yes. I think. I had a 25amp laying around, no difference.
Is it the stock fuse type?      Yes.
Is it the stock fuse holder?      Yes, although, I already tried another.
Is your whole electrical system stock?       I think so.
Are all your electrical components stock?       I think so. I did swap out the ignition switch and wires since they were cleary faulty.
Have you ever cleaned any of the electrical connectors on the bike?      Yes, I've been trying to look at every wire since this problem cropped up.

Have you ever cleaned the fuse holder contacts on the bike?      No, but I replaced it to eliminate the possibility of that being the problem.

Does the fuse feel hot to touch during operation?      Yes. But not super hot. Just warm.
Did you just say ouch?       Heh heh heh, nope, it doesn't get that hot.
Have you searched for the topic "WTF Fusebox" ?         Hmmmmm, I better try that.
Do you need six more questions?      Not, yet, Thanks!

I assume my next move is to take some measurements with a multimeter when it's running fine and when it's acting up. I just was wondering if someone had some specific things I should look for. Thanks.

Offline number13

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Re: Help! I keep blowing my main fuse....
« Reply #27 on: May 25, 2006, 01:11:27 PM »
It sounds a lot like heat induced resisitance. I had a similar problem with a breakerless
ignition on my car. Ran good for about 20 minutes, dies, sits for 20 minutes, runs fine.
I eventually figured it to be a bad ground connection.

I have had this occur on my bike as well and it was the same problem, bad ground.
So, have a good look at your battery ground cable.
Clean the connections with some steel wool and be sure
both ends are firmly secured.
best o' luck!!


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Offline Caferacernoc

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Re: Help! I keep blowing my main fuse....
« Reply #28 on: May 25, 2006, 01:56:55 PM »
Yeah, I've been reading the "WTF fusebox melted" and "Overcharging" posts in the archives. Just what I was afraid of. Time to unwrap more electrical tape and keep checking/cleaning the wires and connections.. I will also double check the battery terminals and grounds. It's so frusterating because I keep thinking I've got it licked and then I go for a 15 minute or more ride and poof. Back to square one.

Offline oldbiker

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Re: Help! I keep blowing my main fuse....
« Reply #29 on: May 26, 2006, 01:34:46 AM »
This type of intermittent fault is the most difficult to find. I can only suggest that you isolate every circuit and then reconnect them one at a time (starting with the ignition circuit) until you find which one is causing the problem. You can then check all the components in that circuit to find which one is heat affected.

Offline Terry in Australia

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Re: Help! I keep blowing my main fuse....
« Reply #30 on: May 26, 2006, 02:40:31 AM »
One of the improvements that Honda made from 1973 was to change the single fuse on the CB750 to a 3 fuse system, thus allowing you to isolate the problem, which is quite common. As terrible as it sounds, I always had a piece of foil out of a cigarette packet in my jacket pocket in those days to wrap a blown fuse in if there was no other option, I never melted any wiring by doing this, but never felt good about it either, but it beat the ass outta pushing a dead bike home, ha ha!

I almost always found that the fault lay in the wiring jammed into the headlight shell, so make sure that you clean all the connectors and pop them back together ensuring that you've got them correctly connected, hopefully you're not color-blind like me, which makes wiring a nightmare. Also, check the wiring coming out of your switchblocks for broken insulation, particularly if you've recently changed out your handlebars. Cheers, Terry. ;D
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Offline nsargeant

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74 Cb550 popping main fuse
« Reply #31 on: May 29, 2006, 05:21:32 PM »
For some reason my cb550 started popping the main fuse over and over.  I went out to start it one day and turn the key on and nothing.  So I check the fuses and the main is popped. I replace it and drive down the road about 500 yards and everything shuts off.  I put in another fuse and as soon as I turn the key on it pops. it did that 4 times as a randomly wiggle wires and the gas tank and such.  On the 5th fuse it works.(lucky me  it was my last one)  So I hurry up and speed home. So i go out to my bike to ride it today and go down the road to realize I forgot something and when I went back outside to ride it I turn the key and nothing again. Put in a new fuse and it popped.  Where do I start to try to figure out why my 550 is blowing fuses?
thanks, Nathan

Offline TwoTired

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Re: 74 Cb550 popping main fuse
« Reply #32 on: May 29, 2006, 05:37:44 PM »
Search for and read the topic that contains "WTF Fusebox".

Or, insert an amp meter in line with your fuse to determine actual current draw.
Lloyd... (SOHC4 #11 Original Mail List)
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Offline csendker

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Re: 74 Cb550 popping main fuse
« Reply #33 on: May 29, 2006, 05:40:57 PM »
First, I assume you have the proper size main fuse (15A) and have it in the proper fuse holder. I say this because I have personally found that jamming the 7A headlight fuse into the 15A main block doesn't work very well.  Then, make sure you have the right size fuses, that is the 1" long ones, not the standard 1.25" auto fuse.  You can get them at any auto parts store, you just have to dig for them.  The long fuses don't fully seat into the block and can cause some hot spots.  You also want to clean the blocks to get rid of any crud that has built up.  This will also improve the flow of juice, lessening the chance for a pop.  If it's not the fuse block, it could be a short that doesn't show up until that first bumb you hit, or a lot of cruddy connectors that are increasing the overall reisitance of your harness. There may be some screwed up electrics, but I'd have to think about that a bit more. Start with the obvious, the right size/rating fuse, and clean everything in sight up as much as possible.
Actually runs --> 1975 CB550-K1
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Offline oldbiker

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Re: 74 Cb550 popping main fuse
« Reply #34 on: May 30, 2006, 12:38:24 AM »
Don't forget, a good way to find a short circuit is to replace the fuse temporarily with a 12v bulb. This will light because of the fault and you can then go round the wiring till you find a wire or component whoch causes the light to go out. Eureka, you have found the problem. While you're doing all tjhis the bulb protects the battery and the wiring.

Offline puppytrax

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Re: 74 Cb550 popping main fuse
« Reply #35 on: May 30, 2006, 03:50:02 AM »
Search for and read the topic that contains "WTF Fusebox".

Would that be "wtf? fusebox melted!?" - http://www.sohc4.us/forums/index.php?topic=2206.0

Doesn't seem to have reached a successful conclusion yet...
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Offline Bob Wessner

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Re: 74 Cb550 popping main fuse
« Reply #36 on: May 30, 2006, 04:20:09 AM »
Quote
Don't forget, a good way to find a short circuit is to replace the fuse temporarily with a 12v bulb. This will light because of the fault and you can then go round the wiring till you find a wire or component whoch causes the light to go out. Eureka, you have found the problem. While you're doing all tjhis the bulb protects the battery and the wiring.

Nice and clever little tip, thanks.  :)
We'll all be someone else's PO some day.

Offline TwoTired

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Re: 74 Cb550 popping main fuse
« Reply #37 on: May 30, 2006, 09:00:35 AM »
Search for and read the topic that contains "WTF Fusebox".

Would that be "wtf? fusebox melted!?" - http://www.sohc4.us/forums/index.php?topic=2206.0

Doesn't seem to have reached a successful conclusion yet...

The original problem thread was resolved by post #12.  Disscusion was hijacked and continued without followup from the hijacker.

The issues and actions were on topic and very likely related to your bike's problem.  Did you read the whole thread or just jump to the end?  If you are trying to economize your reading, then just read my posts within that thread, I suppose.

Good luck!
Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline Chris Schneiter

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Re: 74 Cb550 popping main fuse
« Reply #38 on: May 30, 2006, 12:33:14 PM »
The first summer I had my 750, that kept happening to me..one day, just to get home, I put in a 20amp fuse..I think it's still there..in the meantime, I've traced every wire on the bike, and found a lot of bare wires. I found a bunch under the seat, next to the fusebox...I taped them all, and eventually, the problem cleared up....the most vexing areas for me though have been the ones you can't see...inside the headlight, the junction between the main harness and the front end (under the tank). Check all connections! and make sure that they are routed properly...I had one connection in that bunch that was routed wrong, and one wire was shorter than the rest, so when I turned the handlebars sharply, the wire would pull out...of course I'd check the fuse and no blow...I got stranded a lot for a while...
By far the worst short was last year when the starter switch/headlight cutoff switch disintegrated...I'd be riding down the road, and all of a sudden, my headlight would go out...finally, the starter didn't work either, and the button stayed in...finally, I put a new pushbutton for the starter, and a second light switch in...my starter works fine now, but the most remarkable thing is that for the first time in nearly 4 years, my headlight is as bright as any newer bike, and everything works as it should!
I guess what I'm saying is with electrical problems, everything is connected. If you are blowing fuses, or even have a dim light like I did, you have a short, and your life will be miserable until you find it. For me, trouble shooting my bike was like having a handicapped wife...I love her to death, but eventually,through loving care, I was able to find areas  in her that were especially problematic (loose wires under the seat, under the tank, in the headlight etc.), and once I found those, it became much easier to keep her comfortable.
CB750 K6

dillwad

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Main fuse heating up and opening
« Reply #39 on: June 18, 2006, 05:48:14 AM »
Well my 550 is on the road i know i dont post here to much , But here is my problem.
Bike starts runs everything is good excpet after driving it a bit  The main 15 amp fuse gets so hot  it un-solders itself.
It does not blow but the end cap seperate. And it does it when sitting there .
I am leaning towards the headlight  not sure what it is  or what the stock watt rating is.
But something is drawing a butt load of current.
Also  with the bike off i have voltage going tto the fuse  This does not seem normal to me .
Any help would be great

Offline grumburg

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Re: Main fuse heating up and opening
« Reply #40 on: June 18, 2006, 07:19:48 AM »
Had the same problem. Would start by removing the headlight. Make sure the clips are tight in the plastic 3 prong plug and there is no bare wire. Also, check wiring around where headlight plug will be when light is pushed back in. Try circuit before putting light back in. Should solve it. Have done 2 550s and had this problem with both.
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Offline csendker

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Re: Main fuse heating up and opening
« Reply #41 on: June 18, 2006, 07:32:32 AM »
Try pulling the fuse and cleaning up the fuse block really, really good.  Also make sure you have the right size fuse - length that is.  These take a 1" fuse, not the 1-1/4" auto size.  You can jam one in, but you don't get full contact, which equates to heating it up by pushing the current throught a smaller contact area.  Also start to clean up all of your bullet connectors.  A tiny additional amp draw caused by each cruddy connector will begin to add up with the 10 zillion connectorn on these bikes.
Actually runs --> 1975 CB550-K1
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Offline Bob Wessner

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Re: Main fuse heating up and opening
« Reply #42 on: June 18, 2006, 07:44:13 AM »
Quote
Also start to clean up all of your bullet connectors.

Along with the connectors, make sure all your ground connections are clean and solid as well.
We'll all be someone else's PO some day.

Offline MRieck

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Re: Main fuse heating up and opening
« Reply #43 on: June 18, 2006, 07:57:58 AM »
Also make sure your battery is not dry.
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Offline TwoTired

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Re: Main fuse heating up and opening
« Reply #44 on: June 18, 2006, 08:05:42 AM »
check our the thread "WTF fusebox melted"

Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline emmaus777

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Main fuse blows
« Reply #45 on: July 13, 2006, 02:56:26 PM »
Alright... this is my first bike so go easy :-\ . It's a '77 550. Last night the fuel valve was left on after my brother took a short ride. Fuel started leaking out the carburetors. I drained the carbs but it wouldn't even crank. I checked the spark plugs then replaced them, still no luck. I checked the battery, it had a charge. So I check the fuses and the main fuse was blown. I replaced it but the moment I pressed the start botton it blew again. I can kick start it just fine and had no problems before the fuel incident last night. Electrical is my weakest area so I'm just hoping you guys can give me a clue as to what part of the ignition system might be the problem.

Thanks for the help,
Robb
'77 CB550F Supersport

Offline TwoTired

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Re: Main fuse blows
« Reply #46 on: July 13, 2006, 03:21:19 PM »
Electrical system analysis is largely a numbers game.  Particularly when troubleshooting from afar.  The more numbers you share, the more meaning full your responses can get.

Battery charge voltage?

Main fuse replaced with correct amperage? (number)

Does your starter button feel right?  When the Master brake cylinder leaks fluid into the bar controls, it can destroy the starter switch inside

Other than that, the yellow/red wire controls the starter solenoid between the starter button switch and the solenoid.  Disconnect that at the solenoid. And measure resistance between it and an engine case screw or the battery minus terminal.  Zero resistance indicates that wire is grounded to the frame somewhere.  Find where the wire is chafed and insulate it.

Cheers,
Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline number13

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Re: Main fuse blows
« Reply #47 on: July 13, 2006, 03:59:11 PM »
I second that.

However, when that happened to me
the culprit was a bad fuse holder, They will
get corroded over time and corrosion creates
resistance, resistance creates heat, heat make fuse go boom.
try cleaning the fuse holder also make SURE
the battery ground cable (the black one) is clean and
securely bolted to the frame.

lots o luck!!
Bikes parked out front mean good chicken-fried steak inside.

Offline emmaus777

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Re: Main fuse blows
« Reply #48 on: July 13, 2006, 05:04:45 PM »
Thanks guys,
I'll take at closer look and see what I can find.
Robb
'77 CB550F Supersport

Offline csendker

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Re: Main fuse blows
« Reply #49 on: July 13, 2006, 06:33:43 PM »
...and get the right size fuse: 1"; not the 1-1/4" auto fuses.  The contact area is reduced with the oversized fuses - smaller contact area, higher resistance, higher heat and more booms.  You should be able to find them in the local auto parts store, just look real hard at the fuse display, they're usually tucked way down in the bottom.  By the way, the main is a 15A fuse.
Actually runs --> 1975 CB550-K1
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