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Mystery Fuse Keeps Blowing

  • Thread starter Thread starter jbfrench
  • Start date Start date
J

jbfrench

Guest
So recently while riding my signals, fuel gauge, and gear indicator went out. When I went to check the fuse I noticed that it and another fuse blew. I replaced the signal fuse and everything was fine but when I replaced the other fuse it blew immediately. I managed to ride home without any problems. When I checked my service manual the fuse wasn't listed. It is the 30 amp fuse that runs right off the battery and is usually mounted by the starter solenoid. I figured it could be the solenoid so I went to start the bike back up and it fired fine. No problems anywhere. Does anyone know what this fuse is hooked up to?
 
What year and model is the first question you'll be asked. Typically, I think there are four fuses installed: main plus one for each of the 3 circuits. There is a fifth unswitched circuit that's unused from the factory. I don't think any of the factory circuits use a 30A fuse, so maybe something was added by a previous owner. Any aftermarket accessories like heated grips or extra lights?
 
Is it a glass fuse? Or a blade?

Let's have some more information, and a few pictures. You can include more than one per post if you use a web-host for your images
 
In my confusion I forgot to post the really important stuff. 1980 GS550L. I replaced the glass fuses with blades about 2 months ago but I was very very diligent in making sure that the right connections were made. In fact, after switching to blade fuses my fuel gauge started working properly again. But that's a different story. There are no aftermarket accessories. When I replaced it the fuse was by itself and mounted to the starter solenoid in what looked like an OEM mount.

This is the OEM fuse holder that I had replaced originally.
tumblr_nv3mw4KV4W1spijjto1_500.jpg

This is the same red wire from the above image. The original fuse holder was mounted where the screw for the current fuse box is.
tumblr_nv3mvvjo9n1spijjto1_540.jpg
 
No fuse should be a 30.
Main is a 15 and others are 10s. (at least on 850s and 1100s)

If main fuse blows immeadiatly that sounds like a problem with the R/R.
Try disconnecting the r/r and see if main fuse holds then.
But this doesn't explain any thing about your signal fuse.

.
 
Redman said:
No fuse should be a 30.
Main is a 15 and others are 10s. (at least on 850s and 1100s)

If main fuse blows immeadiatly that sounds like a problem with the R/R.
Try disconnecting the r/r and see if main fuse holds then.
Click to expand...

I was thinking the same thing. Of late, there have been a number of R/Rs connected directly to the battery with rather large amperage fuses...
 
I looked it up here http://www.cmsnl.com/suzuki-gs550e-1980-usa_model16029/partslist/93025.html#results and can't see any such thing...just a 4-fuse block and as said above nothing more than 15A and some 10A so I think someone fudged that from some other bike or boat entirely and it's not OEM.
The starter motor itself has no fuse.... I think someone was trying to run the whole bike somehow with that single fuse. (on the other hand, It's true some old Honda's have a single 30Amp master fuse link but they are more a Fusible-link not a glass fuse....)
 
If you wired your R/R the questionable way you would need at least a 20 amp fuse(sometimes they need to go higher).

All those bare power out on the fuse box are very scary. I would get some shrink tubing.
 
Last edited:
My 850 had a problem for the longest time of blowing the main fuse and the signal\fuel gauge\gear indicator fuse. When I tore down the bike over the winter it was pretty obvious. The hot terminal of the horn was a few thousandths from a bracket on the frame. Rotated horn, OK since.
 
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