ZX9r and IG fuse

[cowboyz]

Right. something new for the 9

Its started randomly blowing the IG fuse.

I had a manual round here somewhere in pdf format for it but looks like its gone west.

It seems a bit random so I am thinking its a wire thats worn through the shealth and touching the frame shorting out with vibration is my first thought but cant find anything obvious.

Any ideas? Twice in 2 days its gone bang and it cuts the igniton much like flicking the kill switch. Replace fuse and its back to normal again.

thoughts?

[kwaka_crasher]

It seems a bit random so I am thinking its a wire thats worn through the shealth and touching the frame shorting out with vibration is my first thought but cant find anything obvious.

I'd say you're right. Now to find it...

[cowboyz]

frik! your surposed to tell me Im wrong and its a easy cheap fix!

[CookMySock]

It seems a bit random so I am thinking its a wire thats worn through the shealth and touching the frame shorting out with vibration is my first thought but cant find anything obvious.

Yeah that is a common thing.

Be careful not to yank the loom hard, as you will dislodge the fault completely and then you will never locate it. It probably won't fault for some time after that, which is and isn't a bad thing.

Wriggle the loom back and forth gently until it faults, and try to track down the area. Eventually you will get it right down an area a few cm across until its a matter of just a fingertip touch, and then you are right on top of it.

Take your time.

Steve

[cowboyz]

turns out it may be the heated hand grips playing up.

disconnected them andits come right. will see in next few days

[CookMySock]

turns out it may be the heated hand grips playing up.

Had that happen to me too. After three controllers, I threw the piece of shit in the bin and wired them to my headlight. End of problem.

Steve

[kwaka_crasher]

turns out it may be the heated hand grips playing up.

disconnected them andits come right. will see in next few days

I wouldn't wire them to the IGNITION circuit. I'd have a separate fused feed direct from the battery through a relay controlled by the ACCESSORY circuit.

[cowboyz]

i had them wired direct to battery. i suspect they failed and causign a spike in the battery. hence recitifier packing a mental with it blowing th eignition fuse. thats my theory and im sticking to it. until it plays up again!

[cowboyz]

anyhow.. after 2 days we finally sorted it with the help of meanies garage and sparkles electrical skills.

Originally I thought it was a wire rubbing on the frame. couldnt find it. Took heated hand grips off and it came right. Right faulty handgrips. Problem fixed. Rode it round for over a week and then it left me stranded on the cheltham striaght. huge thanks to the guy who thought I needed kiwifruit... (WTF?) and to 86, mo, and Ynot and co for the rescue vehicle.
Put it in meanies shed and took it apart. Thinking that it must be a dodgey connection on the fuel pump.. Disconnected fuel pump and fuses stopped blowing. Right.. thats the problem. 5 mins later fuses started blowing again.. Right.. look at relays. disconnected relay and fuses stopped blowing. 2 mins later fuses started blowing again. Got sparkles onto the job and ripped everything we could find out and put it back together again and the bike come good. Bit concerned that we hadnt actually fixed anything but crash started it and it started and run. Bit confusing so I started wiggling wires and found wire to the starter relay was rubbing on frame and arcing on the packrack. YAY! Finally found it. Repaired and bike is good for another 140,000km!!!

Huge thanks to all who helped sort this. Hate having my bike out of action. Will be at the bikeio tomorrow now!

[CookMySock]

Bit confusing so I started wiggling wires and found wire to the starter relay was rubbing on frame and arcing on the packrack. YAY! Finally found it.

Congrats!

Yeah thats the way to do it. Just wriggle gently until you hear a fuse go "snap", or you see a spark leap out of somewhere.

You don't need mechanics and sparkys to find shorts.

Steve

[CTD]

Repaired and bike is good for another 140,000km!!!

140,000km??

Nice work. Any major issues in that time?

I have fond memories of the two 98 zx9r's I had. What great bikes they are.

[cowboyz]

140,000km??

Nice work. Any major issues in that time?

I have fond memories of the two 98 zx9r's I had. What great bikes they are.

None. This is the first time the bike has stopped on me and it was really a minor. I could have fixed it on the side of the road if I knew what it was.
It gets its oil dumped every 5000k and new filter every 10,000. I use the cheapest oil I can find. Only once I have topped it up with 500ml of oil between changes. Highly recommended bike!