Keep blowing a Fuse !!!????? --> '01 CBR600F4i

DC-F4i · 06-02-2009, 8:44 PM

OK.....here it goes....I keep blowing a fuse..."Sub fuse F (20A) (inside the fuse box - controls Fuel Injection, connects to the engine stop relay)"

I started off with replacing the Regulator then the Stator since my battery wasn't charging. The battery was good by the way...NEW. In addition, the bike would seem to lose power at a steady speed...like 40 mph. The RPM's would jump up and down so the assumption was that the Regulator or Stator was going out and not supplying the bike with enough power. This was an easy fix as far as I know....

When I put everything together, which went smooth, I started the bike with a full battery and it ran for about 5 minutes during warm up and the 20amp fuse blew. I put another one in and it blew immediately when I flipped over the engine stop switch to ON.

I've checked all the wiring and harness connectors without taking them apart yet. I've made sure everything is connected and grounded as far as I can tell. I've checked the relays, the fuel pump and the engine stop switch. Everything seems to be fine. I've looked at connections with a meter (which I have very little experience with.) and everything seems fine.

Does anybody have any idea what I should be looking at? or testing with the Voltage meter? This has been so frustrating!!

It seems to be another problem entirely but maybe I'm wrong...did I "F" something up?

Any help would be greatly appreciate...thanks guys!

MACI4LIFE · 06-03-2009, 12:22 AM

logically thinking. if a component is drawing too much current then it'll cause the fuse to overheat and blow. you may want to start by testing the current draw of the FI system.

best thing to find is a wiring diagram for your bike and follow the wires.

DC-F4i · 06-03-2009, 1:44 PM

I have a wiring diagram and I've followed the wires to the Engine Stop switch, relays, & fuel pump. I've tested the wires with a meter and again they seem fine. What could be drawing too much current? You mentioned the FI system...is there something I'm missing within that system that could be drawing too much current?

Keep in mind that everything else works fine....the engine turns over....plenty of power...lights & guages OK. It's just the fuel pump won't prime because the fuse blows immediately when the switch is turned on.

One thing I did do is when I uplugged the harness that the gauges and lights were attached to (the whole front fairing was removed), I turned everything on and the fuse didn't blow but as soon as I attached the harness together it blew. I assumed it was only connecting the circuit so I don't know if it tells me anything.

I'm going to get another 10 fuses or so and do some more testing....I feel like I'm pissing in the wind here.

Sideshow bob · 06-03-2009, 1:50 PM

this sounds like the problem i had the other week with my gixxer.....

one of the solder points in the switchgear was shorting agains the bars.... as soon as i turned the ignition on it would pop a fuse

DC-F4i · 06-03-2009, 2:04 PM

I thought that too. I pulled it apart and it looked O.K. I wired the two wires together anyway with the assumption that it might be something internal and still blowing a fuse. But, I think I'll take the whole strip of wiring a take it apart and look at it. You might have a good thought since that wiring seems to be the closest to metal (along the bars) than any other wiring.

The wiring on the tip over sensor seems good too but could a faulty tip over sensor cause it to short the whole system?

Sideshow bob · 06-03-2009, 2:12 PM

mine showed up after i tightened the switchgear down.... with it off the bars no blowing fuses....
I just insulated the bar... problem solved

MACI4LIFE · 06-03-2009, 6:11 PM

A: Grab a tea and let the wind die down

B: it sounds like you're getting close to localizing the problem. now the next trouble shooting step is to plug the harness in and unplug the components that the harness is attached to. ie. unplug whichever lights and gauges you can and then one at a time start plugging them in. the fuse may pop if you get the right wire. i'd start with all lights first.

Quote:

Originally Posted by DC-F4i

I have a wiring diagram and I've followed the wires to the Engine Stop switch, relays, & fuel pump. I've tested the wires with a meter and again they seem fine. What could be drawing too much current? You mentioned the FI system...is there something I'm missing within that system that could be drawing too much current?

Keep in mind that everything else works fine....the engine turns over....plenty of power...lights & guages OK. It's just the fuel pump won't prime because the fuse blows immediately when the switch is turned on.

One thing I did do is when I uplugged the harness that the gauges and lights were attached to (the whole front fairing was removed), I turned everything on and the fuse didn't blow but as soon as I attached the harness together it blew. I assumed it was only connecting the circuit so I don't know if it tells me anything.

I'm going to get another 10 fuses or so and do some more testing....I feel like I'm pissing in the wind here.

ghbzorro · 06-19-2009, 8:35 AM

Have you found the damaged wire that is causing the short?

DC-F4i · 06-26-2009, 12:17 AM

After checking every wire...every relay...every part you can think of...putting in hours of time and frustration and many beers. It was the last thing I would have thought. -> The ECU !!

I bought one off of eBay for $150.00 and problem solved. Now I just need to make sure the charging system works properly.

I appreciate your help though. I learned how to break it down and put it back together and learned all about the electrical system. I got a lot out it!

DC-F4i · 06-26-2009, 1:54 PM

I wanted to follow up on the last message. When I said the ECU, it was the black/white wire going to the ECU. It also goes to the Engine Stop Relay and the Fuel Cut Relay...FYI. There must have been a short or something in the ECU where that wire was connected...not sure. I hate to tell you how I really found the issue but it worked. I wanted to follow up just in case somebody runs in to a similar issue. Thanks again!!

c0nn0r147 · 06-30-2009, 6:47 PM

hey for a kinda beginner bike i already know how to ride but it will be my fist streetbike of my own thats bigger then a 110 would a cbr600f4i be ok for my first bike

DC-F4i · 06-30-2009, 6:49 PM

I think a CBR is an excellent first bike...easy to ride.

c0nn0r147 · 06-30-2009, 6:50 PM

well i need the best advice anyone can give me to convince my dad a lot of people say a 125-250 would be the best bike but i say that after a year im gonna want something bigger what was ur first bike

tunil · 07-03-2009, 12:51 PM

im having the same exact problem right now on my 929. can you please tell me how you found that the bl/w wire going into the ecu was bad. i think mine is shorted internally in the ecu. if i put mt ohm meter onto the bl/w pin in the ecu and the other lead to the ground wire pin in the ecu and they are connected somewhere internally in the ecu. im just trying to verify this is the problem before i replace it.

DC-F4i · 08-28-2009, 3:50 PM

Sorry, I know it has been awhile since the last question. I'm sure it's too late but I'll tell you any way. Don't do this way....use a voltage meter. I was lucky when I did this desperate action but....

I jumped the fuse box, where the fuse was blowing, with a jumper wire

. The wire that started smoking was how I was able to trace the problem. It led to the ECU and started smoking at the base of the ECU connection for the fuel injection connection. I knew then that the ECU was the problem. I replaced it....fixed.