Darn fuse keeps blowing

[jason_S]

When I hit the starter switch.  It doesn't do it every time, maybe 1 in 10 -15, sometimes more, sometimes less.  Sometimes when I try it, the headlights will dim, but the starter won't turn or anything.  Then If I keep hitting the switch the fuse will blow.
 
I took it in to the dealer, since it was still under warranty, and they had it for a day and then told me they fixed it.  Well, the fuse blew again a couple days later and that's when I found out that the dealer's solution to the problem was to replace the 20 amp fuse with a 25 amp.  So, I called them again, now they are saying it must be the starter switch, and they are ordering a new one, which will take about a week to get here.

My question is, has anybody else had this problem?  Is the switch something I could take apart and fix myself, or is it not really user serviceable?

[johncam4]

:dunno:
warranty is nice

[Rema1000]

I'd let them fix it while under warranty.  If you replace the starter switch, and the fuse keeps blowing, then they may claim that you screwed it up when you tried to fix it, and that they are not responsible for fixing it anymore.

If the fuse only blows when operating the starter, then I'd guess that either (A) the starter is taking way more juice than it should (internal short?), or (B) somewhere in the wire, between the starter switch and the starter, there is an intermittent short to ground.  I'd let the dealer chase this one down.  

And I'd yell at them for putting-in an over-spec fuse.  If you had done that (instead of the dealer), the dealer could rightfully refuse to fix any future electrical shorts.   Oversize fuses can lead to overheated wiring, cracked and melted insulation...  very bad idea.

[John Bates]

I haven't had this problem but just a guess.

If your battery is getting low and you hit the start switch an excessive number of times, because the starter motor is not turning, the fuse may  get hot enough to blow.  

I think a bad start switch will normally fail either open or closed.  So it would not function at all (fail open) or run the starter as soon as the ignition switch  is turned on (fail closed)  (surprise!).

The starter motor does not pull current through the fuse so it would not blow the fuse.

[cernunos]

I've never owned a new bike but if I ever do and it messes up while in the warranty period they WILL fix it...I've gotten pretty good at raising HE** with incompetent dealers when it comes to those things. The squeaky wheel gets the grease so...squeak like a muthaf*****. Love the little GS and the forum.

C.......

[Rema1000]

The starter motor does not pull current through the fuse so it would not blow the fuse.

Doh!  I didn't realize that.  I'm not sure that I like having an unfused wire from the relay to the starter.  The intermittent short would have to be between the starter switch and the starter relay.  Unless the dealer did some checking, and found the source of the intermittent short, then I don't see any reason why changing the switch would fix it.  You might inpect the wire from the thumbswich to the relay (behind the battery on the right, on mine), and see whether you see any cracked insulation.  If you find some, point it out to the dealer.

[Cal Price]

If I were you I would shove it up the dealers ........., well you get the picture! get a warranty job done, if you do it they will say you have invalidated the warranty. Incidently i have never had a fuse blow but I carry a spare with the tools, I guesse you do now.......

[jason_S]

Unless the dealer did some checking, and found the source of the intermittent short, then I don't see any reason why changing the switch would fix it.

This is kind of what I'm afraid of.  Since all they did (apparently) was put in a higher amp fuse, I'm not convinced they actually checked any wiring to see if they could find a short.  Unless maybe they did check and didn't find anything, so they are assuming there has to be a problem within the switch.  Argh, I just don't trust dealer mechanics, especially since they pulled this crap with the fuse.  

And yeah, I carry a spare fuse now, well, a spare box to be exact.  Good thing too, cause one time it blew, and I replace it, then started it up and forgot to put the sidestand up before putting it in gear, which of course killed the engine (stupid safety feature   )  Then I tried starting it again and the fuse blew again.   :x

[cernunos]

Jason-S...GO RAISE HE**!! Don't take that shaZam! from them. If it's under warranty it's under warranty. And if they put in a fuse that has a higher amp rating than specified they could possibly be liable if you were to have a fire. GO RAISE HE**!! Love the little bike and the forum.

C.......

[jason_S]

Jason-S...GO RAISE HE**!! Don't take that shaZam! from them. If it's under warranty it's under warranty. And if they put in a fuse that has a higher amp rating than specified they could possibly be liable if you were to have a fire. GO RAISE HE**!! Love the little bike and the forum.

C.......

Oh, it'll be taken care of under warranty for sure.  I didn't even think about the fact that they could deny warranty coverage if I worked on it myself.  I just hope it's really the switch that's bad, I don't want to have to take it back in a couple weeks to have them fix something else.