help troubleshooting blown fuse - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 3 Old 09-21-2017, 11:50 PM Thread Starter
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Join Date: Feb 2013
Location: SE Ohio
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help troubleshooting blown fuse

I'm not very good at troubleshooting electrical issues so I could use some help. I was riding home the other night at dusk and I lost my headlights. When I got home and investigated, I found that my fusepanel relay kit had blown the main 30 amp fuse. I also have the eastern beaver light switch relay kit and it is powered through the insea 6 circuit fusepanel , which is why I lost my headlights. None of the fuses in the fusepanel had blown and there are 4 active circuits with fuses from 5 amp to 15 amps. (Headlights, GPS, Gerbing Connector and Aux lights). All of the fuses in the fusepanel are much smaller than the main fuse that blew. Of the items routed through the switchbox, only the headlights (15 amp fuse) were active when the fuse blew. I put a new 25 amp fuse in the fusepanel relay kit, just to make sure the original fuse wasn't defective and it worked for a couple rides, then it also blew.

This would lead me to believe that the problem is between the battery and the fuse panel in the fusepanel relay kit. I pulled the fuse panel relay kit and there are no signs of shorting on any of the wires or chafing of the wire insulator and nothing looks/smells like it arced. I figured blowing a 30 amp fuse might leave some noticable signs. My only guess is that maybe the relay is the problem.

Here is the product in question:

30A Single Circuit Fusepanel Relay Kit:



Any thoughts or ideas how I might further troubleshoot the problem would be greatly appreciated.

Current: '12 Dl650, '06 ST1300, '89 Transalp, '84 XL350R, '07 TRX350TM,
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post #2 of 3 Old 09-22-2017, 01:19 AM
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Check to see if the black wire and red wire have somehow melted together. Also see if the fuse blows when the connections at the far left are removed from the fuse panel. If not, something in the fuse panel is shorted out.
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Last edited by greywolf; 09-22-2017 at 01:23 AM.
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post #3 of 3 Old 09-22-2017, 11:38 AM Thread Starter
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Quote:
Originally Posted by greywolf View Post
Check to see if the black wire and red wire have somehow melted together. Also see if the fuse blows when the connections at the far left are removed from the fuse panel. If not, something in the fuse panel is shorted out.
Thank you Greywolf, for the reply. I believe you are correct about it being in the fuse panel. I took it apart and there was melted plastic under one of the positive lug connections. It was the one for my Gerbing gear connector but it only had a 10 amp fuse. There wasn't any moisture in the area so maybe it was a defective 10 amp fuse that wasn't blowing on a power surge. The fuse was a little cloudy and funky looking but it hadn't blown. I could just not use that lug on the fuse panel but I'm going to replace the fuse panel and the Gerbing connector and go from there. I should also probably move the headlight switch relay tap to it's own switched connection so an accessory problem doesn't take out my lights.

Current: '12 Dl650, '06 ST1300, '89 Transalp, '84 XL350R, '07 TRX350TM,
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