main fuse blowing

[Kenstogie]

i have a brand new tbr7 and the main fuse (the only fuse?) keeps blowing....

i was doing all the set up stuff (see Megadans thread) valves, chain, carb, grease front and rear, loctite etc etc....

it worked initially but then i put the tank back on, put the wires behind the headlight fairing assembly and thats when it happened.....

I did unplug/replugged many connectors but was gentle ....or so i thought....

I do have a decent understanding of electrons, ohms law and that stuff but electrical issues in bikes and cars drive me crazy

any thoughts?

[BuffaloChinaRider]

Hey ken, sorry to hear about your electrical issues and it definitely can be frustrating. It sounds like there could be a wire or plug somewhere that is kinked or squeezed or not positioned correctly. I know when I took off my head light assembly, a lot of the wires were just stuffed/crunched and some were being squeezed by the steering. If I were you id take your headlight assembly off and run the bike to see if it continues then go from there! I hope we can help you figure it out.

[Kenstogie]

Originally Posted by BuffaloChinaRider

Hey ken, sorry to hear about your electrical issues and it definitely can be frustrating. It sounds like there could be a wire or plug somewhere that is kinked or squeezed or not positioned correctly. I know when I took off my head light assembly, a lot of the wires were just stuffed/crunched and some were being squeezed by the steering. If I were you id take your headlight assembly off and run the bike to see if it continues then go from there! I hope we can help you figure it out.

yup thats what i thought and did that....but i will look more closely maybe i missed something...

i agree all those connectors and wires are kind of jammed in-between the triple tree and headlight fairing...

[paulsstag]

Originally Posted by Kenstogie

yup thats what i thought and did that....but i will look more closely maybe i missed something...

i agree all those connectors and wires are kind of jammed in-between the triple tree and headlight fairing...

The problem could also be on the left hand side panel as you must have removed it to replace the fuse. Take a good look in that area especially as any positive wire touching the battery or frame ground is going to blow that main fuse.

When i assembled my TBR i did use some zip ties to tidy up the wiring.

The advice about running the bike without the front headlight assy makes good sense, now take it one step further and leave the side panel off too. If it still blows the fuse you will have to look for a wire that is grounding out somewhere if not then add the headlight assy back and try again if nothing then add the side panel back.

Hope you find it

[Kenstogie]

thanks for the tips i am going to take a detailed look tomorrow.... fingers crossed

[Kenstogie]

So FWIW I figured it out... and everything is working now.... I don't know what wire it was but I had a short on a positive lead to a ground...

what I did was checked continuity to ground for all the positives... aka hook up a multi tester neg (black to a ground and probed all the positives till i found the one that read basically no resistance....

Sometimes just looking around helps as you can see a damaged wire or something touching a ground/frame.....

[jongu413]

Originally Posted by paulsstag

The problem could also be on the left hand side panel as you must have removed it to replace the fuse. Take a good look in that area especially as any positive wire touching the battery or frame ground is going to blow that main fuse.

When i assembled my TBR i did use some zip ties to tidy up the wiring.

The advice about running the bike without the front headlight assy makes good sense, now take it one step further and leave the side panel off too. If it still blows the fuse you will have to look for a wire that is grounding out somewhere if not then add the headlight assy back and try again if nothing then add the side panel back.

Hope you find it

I have an orion 250 and yesterday all my blinkers went out - do you have a picture of where your fuse (box?) is located? I can't seem to find mine and I'm thinking it'll generally be at the same place on these bikes.

[Kenstogie]

Originally Posted by jongu413

I have an orion 250 and yesterday all my blinkers went out - do you have a picture of where your fuse (box?) is located? I can't seem to find mine and I'm thinking it'll generally be at the same place on these bikes.

asaik the mighty tao tbr7 has but one in line 10a fuse right off the positive battery wire....but maybe i am wrong

[jongu413]

Originally Posted by Kenstogie

asaik the mighty tao tbr7 has but one in line 10a fuse right off the positive battery wire....but maybe i am wrong

does it look something like this??

[Goob]

Originally Posted by jongu413

I have an orion 250 and yesterday all my blinkers went out - do you have a picture of where your fuse (box?) is located? I can't seem to find mine and I'm thinking it'll generally be at the same place on these bikes.

If it is just the blinkers, then I would find the relay and jumper it out, then try the signals. If they don't work it is the relay. Cheap and easy.

It is unlikely for all of them at once, check all of the connectors to the lights. These are not very robust. I had one light go out and it was the connector not being fully seated.

[Slowboat]

Hey I had that same problem try switching the wires at the battery they seem to be routed wrong from the factory