FZRSupport: the FZROnline Archive

I was riding my fzr600 on the freeway a few nights ago, and the bike lost all power. I quickly saw the main fuse was blown. the next day I went and bought some new fuses. When I went to install it, the main fuse blew before I even had it plugged all the way in. Bike turned off. I'm not really sure what would cause this.

I recently replaced my voltage regulator as it was burnt out and was draining my battery. That was a few weeks ago and its been ok since. I would love to hear what you guys think before I dive into it. My guess its a short/ground somewhere, but i really dont know. seems very strange that its blowing before I even turn the bike on. I have the wiring diagram and have read through a lot of forums and havent seen my same problem anywhere.

that really narrows things a lot. if the short is taking place before u turn the ignition on, than it means that the short is taking place on a wire that is not running directy or indirectly trough the ignition. Look again in the wiring diagram and see what fullfills these conditions.

The main fuse is wired between the ignition switch and positive on the starter solenoid, therefore is wired to the battery positive and is constantly live. A member recently had a similar issue. Before doing anything You've possibly fried the VR, that will in turn cause other issues. When you solve the cause before starting the engine check for any blown bulbs (a sign of a faulty overcharging VR) Read this thread http://www.fzronline.com/forum/viewtopic.php?f=8&t=6300

Thanks for the tips guys. I think first thing I am gonna do is just go ahead and do the vr upgrade. That way I don't fry my stator if I get this thing to stop blowing fuses.

Once I do that I guess I will just start looking for cracked wires or shorts or something I guess. I am gonna go try and tackle this now. Wish me luck.

For the fuse to blow with ignition off the wires from the fuse to ignition switch are grounding down some place.
The usual places are near the steering neck or corrosion / water shorting the ig. switch to ground.

Check the wiring diag for sure as I am working from memory ( never that good at my age and lately I have wired 3 different bikes so that could be a source of memory mix up.)

Another possibility. The VR could be shorting to ground (burnt internals), disconnect the plug. Also check the main fuse holder for signs of overheating.

It was the voltage regulator. I went and checked out the wires that ran just offthe battery and to the starter relay. Seemed like they would make the most sense. Routed it directly from the battery to the main fuse and it blew. So then I tried unplugging the vr. It didn't blow. I went to the local junkyard. No r6 vr's. Found a xs400. 5 pronger. Smaller than the r6 but slightly bigger than the fzr with some cooling fins.

It will hold me over. I'll order an r6 one off eBay Monday and do it right.

Thanks fr the help everyone.

But now you need to know why 2 VR's have failed in such a short space of time. Believe me you don't want anymore fried VR's

1. Was your battery cooked by the first faulty VR. I.E. is it boiled dry, can it take a charge (if the VR cant dump its DC output it will fail)

2. Is the main fuse holder showing signs of overheating (the fuse will eventually blow again)

3. Do you have a custom tail preventing airflow to cool the VR

4. Check your charging system http://www.fzronline.com/wiki/doku.php? ... flow_chart

Also are the pin outs the same on the "xs400. 5 pronger" the same as the R6 VR

Does the bike run? try starting it with the VR disconnected (really hope you haven't fried the TCI)

All i can think of at the moment, and Good luck.

The bike is running fine for now. I took it for a short ride. Guess time will tell. The first time I replaced the vr it was because it was draining the battery. That problem seemed to be fixed after I replaced it. The battery int draining though This time it blew the main fuse.

The prongs are the same as the r6 one. It had all the wires attatched when I got it. 3 white a red and black, so it was easy to decipher and make sure I hooked it up right. No custom tail
or anything.

Glad to here that, you've been lucky.

crosstowntraffic wrote: The prongs are the same as the r6 one. It had all the wires attatched when I got it. 3 white a red and black, so it was easy to decipher and make sure I hooked it up right.

Thank you for that info.