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Blowing fuses, dont know why

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  • Blowing fuses, dont know why

    i just got this bike a little over a month ago, everything have been fine until now, but the other day, i noticed that my gauges werent working. So i checked the fuses, Sure enough, one was blown. I replaced it with a spare, started the bike, and voilla! instrument cluster was lit up like 4th of july. I sat on the bike, put the kickstand up, and blip!....no more lights, i replaced the fuse, and with the stand down and in neutral, i started the bike. Lights galore. I put the kickstand up, and POP! they were off again....any ideas as to why all the sudden this is happening? Its a 2000 Kat 600

  • #2
    Check your wires. Sounds like you have a short, maybe something grounding out somewhere or worn insulation on a wire. I'd start near your sidestand since that seems to be the focal point.

    Long Live the D

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    • #3
      There is a sensor attached to a contact switch activated by your sidestand for the bike to recognize the fact that it's up (the safety system of the bike won't let the engine start or continue to run with the sidestand down if the bike is in gear -- it doesn't care if the bike is in neutral).

      It sounds like one of four places is the primary culprit:
      (A) The wires to the contact switch for the sidestand. Trace them and see if you find any knicks or melted insulation.
      (B) The wires to the gear sensor switch in the transmission. Same deal -- check for knicks or melted insulation exposing the wire to other metal on the bike.
      (C) The wiring bundle going to the back of the dash board above the headlight assembly. Remove the fairings and check the bundle, especially where it crosses from the engine area across the frame (right side) towards the dash.
      (D) The actual ignition switch wires. Follow them down from the ignition lock and again check for nicks or melted insulation.

      I'm guessing that on a 2000 it will either be (A) or (C).

      Good Luck!
      =-= The CyberPoet
      Remember The CyberPoet

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      • #4
        well after more troubleshooting, i have pulled the kickstand switch and reinstalled from the kickframe, and its not the switch persay. i have gotten the bike to run, and put the KS up without blowing the fuse, and have even managed to run through the gears with the bike setting still, and played with the light switches, honked the horn and everything else i can think of to try to make it short, but to no avail. once i move the bike a few feet, it pops. I tried moving it in neutral, and no pop, but when i ride, it pops.

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        • #5
          Could also be the grounding circuit for the dash. Go check that wire bundle headed up to the rear of the dash...

          See this thread for more info:


          You may also want to check my motorcycle electrical diagnostics page and browse through the motorcycle lighting diagnostics page

          Cheers,
          =-= The CyberPoet
          Remember The CyberPoet

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          • #6
            well i tore the whole thing apart tonight, and couldnt find any burn casing of wire, put everything back together, and it seems to be ok, i was only able to ride about 10 feet or so, maybe more before the instrument cluster fuse blew, however it went for about 2 or 3 blocks and was still going....who knows, ill put the fairings back on tomorrow, and go for a ride to see if maybe something just was jammed up somewhere or something......

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