underseat fuse blowing like crazzy - 600RR.net
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post #1 of 49 (permalink) Old 04-04-2010, 04:37 PM Thread Starter
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underseat fuse blowing like crazzy

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?

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
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post #2 of 49 (permalink) Old 04-04-2010, 04:50 PM
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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.
post #3 of 49 (permalink) Old 04-04-2010, 08:03 PM Thread Starter
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The only fuse that is blowing now is the fuse under the seat, the mini 20 amp. The big 30 amp is fine.

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
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post #4 of 49 (permalink) Old 04-04-2010, 09:19 PM Thread Starter
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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.

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #5 of 49 (permalink) Old 04-04-2010, 09:29 PM
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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.
post #6 of 49 (permalink) Old 04-04-2010, 10:38 PM Thread Starter
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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?

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #7 of 49 (permalink) Old 04-05-2010, 01:35 AM
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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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post #8 of 49 (permalink) Old 04-05-2010, 08:37 PM Thread Starter
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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?

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #9 of 49 (permalink) Old 04-05-2010, 09:03 PM
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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.
post #10 of 49 (permalink) Old 04-05-2010, 09:09 PM Thread Starter
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any idea where I can find that? I am having trouble taking the tail fairing off!

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #11 of 49 (permalink) Old 04-05-2010, 09:19 PM
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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.
post #12 of 49 (permalink) Old 04-05-2010, 09:44 PM Thread Starter
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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.

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #13 of 49 (permalink) Old 04-05-2010, 09:53 PM
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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.
post #14 of 49 (permalink) Old 04-05-2010, 10:45 PM
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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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How to fix headlights... Dreamzboy's excellent write-up
https://www.600rr.net/vb/showthread.php?t=138034
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post #15 of 49 (permalink) Old 04-06-2010, 01:33 AM
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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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post #16 of 49 (permalink) Old 04-06-2010, 04:01 PM Thread Starter
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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

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #17 of 49 (permalink) Old 04-06-2010, 09:02 PM Thread Starter
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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

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #18 of 49 (permalink) Old 04-06-2010, 09:14 PM
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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.
post #19 of 49 (permalink) Old 04-06-2010, 09:14 PM Thread Starter
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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.

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #20 of 49 (permalink) Old 04-06-2010, 09:19 PM
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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.
post #21 of 49 (permalink) Old 04-06-2010, 09:24 PM Thread Starter
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Just visually for the most part. I don't see how bad continuity would break fuses though. Someone said it could be a bad ground but I don't know for sure. Never done electrical work on anything in my life to be honest, this would be the first. I have built engines, but no electical stuff beyond plugging in the connections when the engine was built.

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #22 of 49 (permalink) Old 04-06-2010, 09:33 PM
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I'm sure you know this; but, make sure you don't have any electical wires touching the frame. I kept blowing a fuse once and that was my problem.
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post #23 of 49 (permalink) Old 04-06-2010, 09:35 PM
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A bad ground would just leave an open in the circuit and no fuses would blow, as a fuse is a failure point to create an open circuit. Checking for continuity will help find a short circuit, because of anything other than infinite resistance is seen in a circuit that should be open, there is a short.
post #24 of 49 (permalink) Old 04-07-2010, 05:02 PM Thread Starter
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ok, I checked the fuel pump wire for a short circuit by checking resistance between it and the ground. There is infinite resistance. I cleaned the fuel pump out yesterday and noticed tiny metal shavings (read: microscopic) all around the filter, even past it. I am thinking these may have damaged the pump. Well to be more precise, it is a returnless fuel system, so I think it got the fuel regulator (blow off) stuck, and is making the pressure abnormally high, and leading to the pump drawing more amps than it should. Anyways, I'm off to buy a clamp on volt meter to see how many amps its drawing.

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #25 of 49 (permalink) Old 04-07-2010, 05:06 PM Thread Starter
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oh and will the fuel pump from a 1000 fit you think?

I see a lot of people with 600's having fuel pump troubles, and since I have exhaust, filter, ram air resonator delets & power commander I thought it might be stressing the stock fuel pump a little bit

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #26 of 49 (permalink) Old 04-07-2010, 05:49 PM
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A 1000 fuel pump wont fit, and if the key is off, infinite resistance is good. Still all those other wires to check.
post #27 of 49 (permalink) Old 04-07-2010, 09:32 PM Thread Starter
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alright I checked a lot of wires, I would say all (or very close to all) that apreared related on the diagram.

It runs now, doesn't blow fuses, but the FI light stays on for a bit after starting it. Kinda like what it was doing before It blew fuses like crazzy. I put an amp meter on the handlebars to see what its drawing and it draws about 5-7 at the moment. Still concerned about the fuel pump. Should I get a new one? An 06 one from a 600rr should fit right?

EDIT:
forgot to mention I cleaned the fuel pump in my kitchen sink with a toothbrush and removed any and all dirt, took the filters off and cleaned them as best as I could. Cleaned with alcohol and put some fuel injection cleaner in the tank.

It is running off a 15 amp fuse now and is not blowing that!

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!

Last edited by michaelwood; 04-07-2010 at 09:54 PM.
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post #28 of 49 (permalink) Old 04-07-2010, 11:39 PM
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I wouldn't trust anything that just kind of fixes itself. If you don't find anything... you can always get another wire harness and switch them out.

Ride hard today, Ride harder tomorrow,!
Walk close to Christ today, Walk closer tomorrow

How to fix headlights... Dreamzboy's excellent write-up
https://www.600rr.net/vb/showthread.php?t=138034
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post #29 of 49 (permalink) Old 04-08-2010, 05:22 PM Thread Starter
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it seems like it is running wierd / revs up slower than normal. damn what is up?

Current bikes:
2004 CBR600RR (daily rider, to be raced)
2006 CRF450R
1973 CG150 (off road, future restoration project)
1971 CB100 (being restored)
2006 BWS50 Zuma
Bikes of my (recent) past:
2004 Honda Ruckus, completely built, 55mph on the flats, 60 downhill and/or drafting
2007 Kawasaki Ninja 250
2004 Yamaha R6

CBR600RR Mods:
BMC race filter
Jardine slip on
8987 PENSKE triple adjustable shock
STM slipper clutch
Power Commander III

Gear up or go home!!
michaelwood is offline  
post #30 of 49 (permalink) Old 04-08-2010, 05:50 PM
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The revving thing is probably nothing, but go over all of the wires/connectors you touched again. There is definitely something broken or damaged in there if it all of a sudden stopped blowing fuses.
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