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Discussion Starter #1
The underseat fuse on my 04 600rr is blowing like crazzy. Sometimes I can ride, and other times it blows instantly. The brake light wires were smoking and had a little short in there, so I patched that up but the fuse keeps blowing now. What could this be?
 
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Which fuses exactly are blowing? Since you had a short in the brake light wires, look over that whole area for more issues. When you see smoke, something isn't right.
 

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Discussion Starter #3
The only fuse that is blowing now is the fuse under the seat, the mini 20 amp. The big 30 amp is fine.
 

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Discussion Starter #4
also the front brake sensor doesn't work any more I guess that got fried. I'm thinking its gotta be a relay or a solenoid or something! I don't know why it started doing this. Sometimes it'll start and as soon as I give it gas it'll blow the fuse. Or as soon as I shift fron neutral to first.
 
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That's a bit, odd. A bad relay wouldn't continuously blow fuses. Did you do any mods to the bike before this issue started?

I'm taking a guess here, but there has to be a stripped piece of wire somewhere in the headlight circuit that is shorting out when the bike moves a bit like it does from engine vibrations and the lurching from the chain picking up the slack when put into 1st.
 

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Discussion Starter #6
I did switch out the throttle tube to a yamaha one that fit in almost perfectly just maxed out one of the adjustments but that is about it. I can't really see it being the headlight's because those are still on when that fuse blows I think. I will give it a check though I'm gonna tear everything off tommorow and start checking everything I can.

Do you think I should strip the whole harness down to check, or do the sensors and ends first?
 

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Looking at the schematics, looks like the 20a under the seat is for the "engine-stop" relay, should be a red and white wire and it is the and its gonna be on tab #30 on the relay. My advice would be to find that relay and trace that wire as best as possible. A relay would not cause an excessive amperage condition usually so I would bet its a wire shorting out somewhere in the harness. A quick fix would be to bypass the harness and run your own wire from the fuse to the relay...let me know if you need a better explanation.
 

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Discussion Starter #8
hey guys I ran all the PGM-FI tests, they were all good. I put a new fuse under the seat and it doesn't blow without the ECU (ECM in the manual) plugged in.

So I guess my question is how far can I ride without the ECM plugged in?




no just kidding on that part but for real does this help you guys get an idea of what could be going on?
 
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Not really. Unplugging the ECM just creates an open circuit. There's going to be a short in the r/w wire somewhere. Looks like there is a single wire plug close to the fuse for that circuit. Check the plug for that wire for signs of damage.
 

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Discussion Starter #10
any idea where I can find that? I am having trouble taking the tail fairing off!
 
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You should be able to see it from the underside of the fuse plug under the seat. Just follow the wire until you find the plug or a damaged spot.
 

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Discussion Starter #12
ok one of the big red wires goes to the ignition. Could this problem be to much graphite in the lock? Remember, graphite conducts electricity.

I responded before refreshing and seeing your old post, I'll check that out. It all looks good so far I'm gonna cut the harness open.
 
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No, it wont be the ignition. The only place the issue can be is in the wire, or at the relay, but since it's blowing over and over, it's not the relay since it's obviously working.
 

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The best way to find the problem is to get a wiring diagram found in the service manual. It will show exactly where that wire goes. I have a couple service manuals but not for an '04.

If I remember right... that wire runs the power to the engine stop relay and speed sensor and something else. I believe that same wire powers the fuel pump relay among other things.
 

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All I did was a quick search on google and was able to find the pdf for the service manual, would be helpful for you to d\l it and print out the schematic..
 

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Discussion Starter #16
hey so guys I have not traced the wire the whole way down yet, but I was having the FI light come on while riding sometimes. Could it be that the fuel filter is clogged making the fuel pump run extra hard? It also felt like the bike lost power at certain points. I am having 3 friends over today to help so we are gonna trace the whole wire, I'll let you guys know how that goes
 

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Discussion Starter #17
ok the diagram gives this order:
1. PGM - FI fuse (the sucker thats blowing)
2. Engine stop relay
3. Fuel cut off relay
4. ECU OR Gas tank
 
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What sequence of flashes does the FI light put out?
Check that the engine stop relay is undamaged, as well as the fuel pump relay, and fan motor relay.
Check for a short in the fuel pump wire.

I'm not sure if the relays are the same, but try switching the headlight relay with the engine stop relay and see if the problem continues.
 

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Discussion Starter #19
FML

I checked almost every inch of wire on this harness and haven't found anything revealing. Thinking about trying a new fuel pump out.
 
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Have you actually checked continuity with the wires or just visually inspected them? A wire can be damaged without showing a visible sign of it.
 
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