My previous problem was simple, #3 blown. Thanks for setting me straight on that.

It was barely blown, just a little nick out (why I missed it at first).


Today, similar situation; went for a quick pass, hit 100% throttle, Blown fuse #3. But this time it was really blown. Replaced it with a 15 amp fuse (all I had), and as soon as I turned the key to "on" it blew again. Disconnected the battery, tried again, reconnected the batt., same result, blew fuse #3 as soon as the key turned.

Pretty sure the fuel pump is the issue. The question is; what to do about it?

I doubt a component is the issue. Most likely you have a red wire with a white stripe worn through and rubbing on a frame part if the bike is in stock condition. Has any non stock wiring been installed? That would be the first place to check. Some 2006 Wees has the wiring harness routed wrongly under the left side painted plastic body panel beneath the seat. The harness was outside the channel meant for it and it would rub on a frame part.

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Pat- 2007 DL650A was ridden to all 48 contiguous states. 2012 DL650A is just getting started.
Nicknames for posting ease on my part, Vee = all DL1000s. Wee = 2004-2011 DL650s. Glee = 2012+ DL650s

Anytime that you blow a fuse, it blows for a reason, if you do not find and fix that reason, you will have the problem again! By just replacing a fuse and riding some more, you are asking for trouble.

I gave a good look at all the electric wiring and was happy to see it all in good condition, no shorts or wear.

unplugged the fuel pump and tested for continuity, sure enough, a closed circuit. When I pulled the pump out there was a washer stuck on the terminals...

Don't have a clue as to how it got there..... hopefully it doesn't belong in there...

Attached Images

	IMG_1663.jpg (90.6 KB, 80 views)
	IMG_1662.jpg (92.2 KB, 74 views)

Wow, good find! Safe to say no one would have expected that.

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Rob

Ride every day, it's good for you.
07 650A | C10 | KLR250

That may be the strangest thing I've ever seen to cause a short. Good find.

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Pat- 2007 DL650A was ridden to all 48 contiguous states. 2012 DL650A is just getting started.
Nicknames for posting ease on my part, Vee = all DL1000s. Wee = 2004-2011 DL650s. Glee = 2012+ DL650s

Ipressive diagnosis and find. Wouldn't have expected that.

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'09 VEE
'07 SE UC
'02 CR 250

Buy a lotto ticket. Bizarre.

What other indications let you know it was the fuel pump? You posted in your first post you thought it was the pump. When the bike dies, fuel isn't pumping anyways, so definitely wouldn't have been my first guess either....

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When was the last time you checked your tire pressure?