Part 2 - ignition fuse sometimes blows when starting

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Following on from my previous thread where my bike just stopped working, an ignition fuse replacement got it going again but it again blew the fuse at the side of the road.

Fast forward a month, I've checked the wiring and every time I do a little fix it will work for a quick test ride, start up again in a few days but randomly blow the fuse the next time I go to start.

I've narrowed it down to the ignition fuse blowing as soon as I hit the starter button, just as the engine begins to turn (but this doesn't explain why it's blown in the middle of riding in the past).

Here's a circuit diagram of the components on that circuit: http://faq.ninja250.org/images/0/07/Start_%26_Igni...

Where do I go from here, PH?

Edited by .blue on Friday 30th September 07:41

Edited by .blue on Friday 30th September 07:44

Edited by .blue on Friday 30th September 09:02

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nervous said:

Reg/ rec?

Should I just unscrew it and inspect the connections for corrosion/anything looking odd?

The owners manual has some conductivity tests outlined in it, I'll have to learn how they need to be done and buy some kit to do them.

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catso said:

As it happens on starting it would suggest something on the starter circuit; from starter button to starter motor?

Which fuse is blowing?

D'oh! Ignition fuse. Updated my first post too.

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So today I found out:

• The starter motor is really awkward to remove, I started trying but stopped as I don't think I'd be able to put it back in even if I did take it out.

• The indicators stopped working for a bit and I had to wiggle the key in the ignition to get them to work. When I then started the bike, the fuse blew immediately. Does this mean that the ignition bit where the key goes in is likely to have a short? There's nothing in the manual about how to remove that - any tips?

• The ground on the ignition circuit looks like this, presumably this is fine?

Edited by .blue on Sunday 2nd October 20:26

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I think I've fixed it. After the fuse blew, I openeded the connectors to clean the pins inside each one and as I was doing that, engine made an attempt to turn over/crank. (I had forgotten to turn the ignition off...).

I have no idea how that happened with the ignition fuse blown - maybe rubbing a metal brush energised the circuit?! I'm starting to believe electrics are more magic than physics.

So 50% sure it's fixed. Time will tell if the fuse blows again...

If anyone can explain how this might have happened, I'm interested to learn more about electrics.