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Discussion Starter #1
I have a 2006 V-Star 1100. It keeps blowing the ignition fuse when I'm riding on the interstate. Not sure where to start on this. Anybody else have this problem and how did you fix it? Any ideas?
 

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First, make sure you are using the correct fuse. If someone replaced it with a lower amperage fuse, and you keep replacing it with the same fuse, there might be a problem.

Second, and probably most important, look for a wire somewhere which has chafed against something and is vibrating or blowing around in such a way that the bare spot is hitting the metal frame of the bike. There is a good chance a wire got pinched under the gas tank sometime when it was removed for other service. Another good place to look is where the wire harness goes into the headlight shell.
 

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First, make sure you are using the correct fuse. If someone replaced it with a lower amperage fuse, and you keep replacing it with the same fuse, there might be a problem.

Second, and probably most important, look for a wire somewhere which has chafed against something and is vibrating or blowing around in such a way that the bare spot is hitting the metal frame of the bike. There is a good chance a wire got pinched under the gas tank sometime when it was removed for other service. Another good place to look is where the wire harness goes into the headlight shell.


+1 on the chaffed wire. If its happening at random times, I would say that's it.
 

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Check your battery connections as well as the properly labeled fuse in the fuse box. If the ground wire is even remotely lose and moving around when hitting bumps it can cause a short and pop the ignition fuse or any other fuse as well.

When I was wiring my LEDs to my bike I shorted it by accident barely tapping the frame and popped the ignition fuse then putting it back together I don't know what it was but it shorted again and did it again.

If everything is good pull the wiring sheets on the other forum and start checking your grounds. Then your leads as well I am sure it is something loose as you stated it happens while on the highway so wind is a factor. Check your headlight wires as well.
 

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Discussion Starter #6
Thanks guys. I thought it might be a chaffed wire too since it does happen at random times and frequently but I haven't found any. Battery is good and fuse is correct. I will check grounds this weekend and keep looking for any possible chaffing wires. I'll post the results when I find it.
 

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Also, had your bike gotten wet lately? and not dried before riding? Yes you can ride in the rain but collecting water that pools can cause all sorts of issues.
 

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Discussion Starter #8
Found a possible culprit going into the lightbar. Taped it up. Gonna ride a bit tomorrow and see if it's fixed.
 
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