 |
|
18 Nov 2008
|
 |
Registered Users
Veteran HUBBer
|
|
Join Date: Oct 2008
Location: West Wales, UK
Posts: 753
|
|
|
XT600E main fuse workaround?
I had to hitch a lift home last night after the XT stopped dead about 100m into my journey. The main fuse had disintegrated (corrosion) and stopped the show - engine, lights, everything. Easily fixed with a new one, but ...
If that failure had happened half a mile further on, I would have been on a narrow twisting A-road in heavy traffic, in the dark and pouring rain. I think I would have been in some danger, as I wouldn't even have been able to see enough to get off the road, and with no lights I would have been a sitting target for the next car/van/truck to come round the corner.
Given the simplicity of the wiring (and simplicity is what I like about the bike), is there a simple way to build in a bit of redundancy into the system? I had this happen in a car once, but the hazard lights worked and gave me enough light to get round a corner and off the road safely. Given the wealth of experience on this forum, I would bet that someone has found a simple modification that would make a blown fuse a bit less of a drama.
Or am I worrying about nothing?
|
18 Nov 2008
|
 |
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
|
|
Hey there, check your electrics... you got something short-circuiting!!
Vando 
|
18 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Oct 2008
Location: West Wales, UK
Posts: 753
|
|
|
Well, sir, that was very clever of you! When I took the fuse out, it came out in two pieces and was very rusty, so I assumed it had died of old age. I tried a new fuse this morning and it started fine. So I got a lift back for it tonight (I've had to leave it at my workplace). It started fine again, but when I put the lights on - pop. Or rather - the headlight came on very dim, so I revved the engine. The headlight went brighter, and then the fuse blew again.
Would I be right in guessing it's a short somewhere? If so, where's the best place to start looking? If I have to rip it apart and check everything, I will, but if there are any well-known failure points it would save me a lot of time.
Thanks Vando.
|
19 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
|
|
Well, you should go to the most important first...
I would check:
the battery contacts
the e-starter(aka starter clutch) conn
the CDI connection
the regulator rectifier conn
the headlight conn
the blinkers (aka turn signals) conn
the lights switch and the turn signal switch
and do check the cables where they come through triple clamps and the fuel tank.. Some people have found that the wires were too stretched and they just teared....
one more difficult thing to check is the alternator....
If you could take the whole wiring out it would be easier to check if any insulation is worn and therefore shorting out...
Keep us posted! 
Vando
|
19 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Feb 2002
Posts: 212
|
|
|
Lighting circuir first
Hi Vando,
I would suggest that you get a few more fuses and find our for sure if you only have a problem when you turn the lights on. Also check if it happens with just side light on, this would suggest a problem with tail light wiring, not headlight wiring (though could still be pilot bulb wiring or the switch)
I would then concentrate on looking for chaffed through insulation on these wires first, and the connections inside the light switch.
You haven't fitted a 100W headlight bulb and spot lights have you?
Good Luck
Mark
|
19 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2006
Location: Edinburgh
Posts: 106
|
|
|
Firstly, do what eveyone else is saying and find the problem. My bike had a few mods before I got it, one of which was the elimination of the fuse. Since everything goes through a protection relay anyway, if there's an overcurrent situation (short, bad earth, flat battery) then the relay chatters and I'm saved the hassle of having to change the fuse. This tends to result in less drastic failures as the lights alone don't normally trip the relay, even if there's a problem.
If you put the supply to your hazards in before the fuse and relay then a fault in the indicators could drain or damage your battery, I'd suggest this would cause more problems than it would solve. Just my 2p worth.
|
19 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Oct 2008
Location: West Wales, UK
Posts: 753
|
|
|
Thanks for all the input. (And by the way, Vando is Bacardi, and I am Richard.)
All components are totally standard, and no obvious frayed wires, either. I checked all the obvious connections when I had it all apart for a full service last weekend. I know what you are thinking, and so am I - trapped a wire putting the tank back on? That's the first thing I'll check. Good idea about the tail and headlight - I put them all on at once, so I'm not sure which circuit was the faulty one. I'll get a pocket full of fuses and a couple of days off work, so I'll let you know. And the bike doesn't have hazard lights - that was a car I was driving.
Great forum, thanks all.
|
19 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
|
|
Hi Richard...
what I meant of the wires passing through the triple clamps is that if the cables are too stretched when you turn the handlebars left/right sometimes that brakes the wiring... there should be a tougher tubing on the wires where they go through the triple clamps to help avoid the friction of the rubbing against the triple clamps from taking the insulation of the wires...
I hope you understand what I just said lol
Vando
|
19 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Oct 2008
Location: West Wales, UK
Posts: 753
|
|
|
Yes, I did understand, thanks! The wires there have a heavy-duty cover which seems to be all OK, but that's only on a casual inspection. I'll get the bike home tomorrow and have a good look.
|
21 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Oct 2008
Location: West Wales, UK
Posts: 753
|
|
|
Sorted, I hope
I've spent the last two afternoons stripping everything down and testing. It turns out (I think) to have been a wire shorting on the headlamp mounting. All the wiring looked good, and with the headlamp cowl off the problem went away, but the clue was than when I put the cowl back, the problem returned. The wires come from below the headstock and up either side of the headlamp, where they rub against the metal of the headlamp mounting. There was clear signs of rubbing on both sides, although even after half an hour with a probe I couldn't find any bare wires. But I have wrapped the wires with a good protective layer of electrical tape, fitted everything back, and it seems to be fine. It looks like it must have been a tiny little short, although even now I don't know where.
It's been a good opportunity to check all the wiring and spray some ACF50 into all the connectors - and I have treated all the hidden bits of the frame while I was at it, so it wasn't a total waste of time.
Thanks to everyone for the advice and suggestions, and a prize to Vando for geting closest. Give the man a coconut.
|
21 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
|
|
Lol thanks for the coconut I'll PM my address LOL just kidding!
I'm just glad I could help!
Just do me a favor... Have fun riding that bike!
Vando 
|
21 Nov 2008
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: Oct 2008
Location: West Wales, UK
Posts: 753
|
|
Oh yes, I have great fun riding it. Every time I get on it, I think what a great bike it is. Not very fast, not very comfy, not very smart, but I love it.
And now that it's running again, I love it even more 
Thanks for the help.
Do Paypal accept coconuts? 
|
9 Nov 2014
|
|
Registered Users
New on the HUBB
|
|
Join Date: Oct 2014
Posts: 7
|
|
|
Sorry for bumping such an old thread but i am in serious trouble.
I have an xt600e 96'a that's shorts the fuse even with the kill switch and the key in the off position.
Everything is switched off but when i try to replace the fuse it blows immediately.
tips anyone?
|
10 Nov 2014
|
|
Registered Users
Veteran HUBBer
|
|
Join Date: May 2013
Location: Wisconsin, USA
Posts: 827
|
|
|
You should just start your own new thread instead of reviving these old ones. Check for any of your red wire touching the frame somewhere. There is the big ones for the starter and one that goes up to the ignition switch. Check around your battery and follow them up the loom. Maybe disconnect the ignition switch to see if it is shorted by installing a new fuse. Disconnect the starter cable from the relay and see if the fuse doesn't blow. You can use a multimeter instead of new fuses if you know how to use it for continuity when there shouldn't be.
|
10 Nov 2014
|
|
Registered Users
New on the HUBB
|
|
Join Date: Oct 2014
Posts: 7
|
|
|
I dont know how to use the multimeter but i will follow your instructions otherwise and just use new fuses instead.
I'll report back here
|
|
Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
|
|
|
Posting Rules
|
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
HTML code is Off
|
|
|
|
Next HU Events
ALL Dates subject to change.
2025 Confirmed Events:
- Virginia: April 24-27 2025
- Queensland is back! May 2-4 2025
- Germany Summer: May 29-June 1 2025
- CanWest: July 10-13 2025
- Switzerland: Date TBC
- Ecuador: Date TBC
- Romania: Date TBC
- Austria: Sept. 11-14
- California: September 18-21
- France: September 19-21 2025
- Germany Autumn: Oct 30-Nov 2 2025
Add yourself to the Updates List for each event!
Questions about an event? Ask here
See all event details
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...
2020 Edition of Chris Scott's Adventure Motorcycling Handbook.
"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)
Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.
Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.
Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!
What others say about HU...
"This site is the BIBLE for international bike travelers." Greg, Australia
"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK
"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia
"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA
"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada
"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa
"This is the answer to all my questions." Haydn, Australia
"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany
Lots more comments here!
Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook
"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.
Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!
New to Horizons Unlimited?
New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!
Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.
Read more about Grant & Susan's story
Membership - help keep us going!
Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.
You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.
|
|
|
helps answer the question - Why Go? Inspirational stories by veteran travellers Greg Frazier (5 times RTW), Peter and Kay Forwood (193 countries), Tiffany Coates (Mongolia Mayhem) and Rene Cormier (University of Gravel Roads).
Get Ready! covers planning, paperwork, medical and many other topics! "Inspirational and Awesome!" See the trailer here!
What stuff do I need - riding gear, clothing, camping gear, first aid kit, tires, maps and GPS? What don't I need? How do I pack it all in? Lots of opinions from over 150 travellers!
break down language barriers, overcome culture shock, ship the bike and deal with breakdowns and emergencies."Just makes me want to pack up and go!" See the trailer here!
Grant demystifies the black art of Tire Changing and Repair to help you STAY on the road! "Very informative and practical." See the trailer here!
Ladies on the Loose! For the first time ever, a motorcycle travel DVD made for women, by women! These intrepid women share their tips to help you plan your own motorcycle adventure. They also answer the women-only questions, and entertain you with amazing tales from the road! Presented by Lois Pryce, veteran solo traveller through South America and Africa and author of 'Lois on the Loose', and 'Red Tape and White Knuckles.'
Cotton or synth sweat-wicking t-shirts with the cool Horizons Unlimited graphic on the front and a snappy slogan (changing every year) on the back.
Show your route on your panniers. Great conversation starter when you meet people on the road!
Motorcycle and travel books to inspire and inform you!
The definitive guide to planning your motorcycle adventure! This insanely ambitious 2-year project has produced an informative and entertaining 5-part, 18 hour video series. "The ultimate round the world rider's how-to!" MCN UK.
Linear Mode
