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Blowing Main Ignition fuse

This is a discussion on Blowing Main Ignition fuse within the Lighting, Stereo, and Electrical forums, part of the Technical category; I've been dealing with a strange issue for the past several months. One day I was driving a little crazy not to bad though, and ...


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Old 07-23-2012, 04:15 PM
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Blowing Main Ignition fuse

I've been dealing with a strange issue for the past several months.
One day I was driving a little crazy not to bad though, and all of a sudden the rhino just stopped.
It took me awhile to figure out what had happened. It blew the main ignition fuse. I replaced the fuse and everything seemed ok.
Several weeks later it happened again. This has gone on for several months where I can go riding and then it will blow the fuse. It usually happens when I am going over big bumps or jumping it a little. Then sometimes it would happen when I was going slow but it wouldn't blow if I was going slow until it seemed to get hot.
Now the fuse is blowing every time I turn the ignition key.
At first I thought it was a short somewhere but I have not been able to find a short anywhere.
Any ideas?
It's an 09 700.

Thanks,

Todd
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  #2 (permalink)  
Old 07-23-2012, 04:42 PM
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Quote: Originally Posted by desertrhino View Post
........It took me awhile to figure out what had happened. It blew the main ignition fuse. I replaced the fuse and everything seemed ok.........At first I thought it was a short somewhere but I have not been able to find a short anywhere.........
Is it the main fuse (30A on the starter solenoid) or the ignition fuse (smaller fuse in the fuse box)? Its a pretty safe bet that you do indeed have a short circuit somewhere. You will just have to hunt some more. Look for bare wires, a loose terminal that may be touching something that it shouldn't, etc. It conceivably could be a broken ignition switch or something similar.

Here is a helpful way to work with a problem like this: put a 12 volt light bulb across the terminals of that blown fuse. The size of bulb is not terribly important, 10 to 20 Watt (tail-light bulb to brake light bulb size) will do nicely. The idea here is that the bulb will light up full brightness if you do have a dead short, perhaps 1/2 to 3/4 brightness if you turn the headlights on, or dimly if you turn on a small load. This bulb will not burn out like the fuse and limits the current flow to protect your wiring while you are poking, pulling and prodding to find that short. Have someone watching the bulb to yell at you you when something changes.

I made a 'test light' like this many years ago. An automotive bulb socket, a couple of wires and some insulated alligator clips (or spade lugs to match the size of the lugs on the fuse).
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Old 07-23-2012, 05:05 PM
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Jump the fuse with some # 10 wire (like motorcyle jumper cables), and see where the smoke comes from-- there is your problem.
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Old 07-23-2012, 06:40 PM
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Quote: Originally Posted by nolids View Post
Jump the fuse with some # 10 wire (like motorcyle jumper cables), and see where the smoke comes from-- there is your problem.
That might work, but could cause collateral damage to the wiring. I.e. smoke everywhere.... Depends on what is doing the shorting. If it is bigger than the wire in between, then kiss the wire in between bye bye.
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Old 07-23-2012, 07:28 PM
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Quote: Originally Posted by SteveS View Post
Quote: Originally Posted by nolids View Post
Jump the fuse with some # 10 wire (like motorcyle jumper cables), and see where the smoke comes from-- there is your problem.
That might work, but could cause collateral damage to the wiring. I.e. smoke everywhere.... Depends on what is doing the shorting. If it is bigger than the wire in between, then kiss the wire in between bye bye.
Of course it works. You are holding the wires so you know when to let go. This is how we fix dirrect shorts in the field. Forget about your light bulbs-- you will be chasing the problem forever.

--Geoff
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Old 07-23-2012, 07:32 PM
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Check user the battery box todd I have seen some Picts on the 700s where the wiring rubbed against the frame... Can't remember how but the wire harness was pinched between battery box and frame........
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Old 07-23-2012, 09:08 PM
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Quote: Originally Posted by nolids View Post
Quote: Originally Posted by SteveS View Post
Quote: Originally Posted by nolids View Post
Jump the fuse with some # 10 wire (like motorcyle jumper cables), and see where the smoke comes from-- there is your problem.
That might work, but could cause collateral damage to the wiring. I.e. smoke everywhere.... Depends on what is doing the shorting. If it is bigger than the wire in between, then kiss the wire in between bye bye.
Of course it works. You are holding the wires so you know when to let go. This is how we fix dirrect shorts in the field. Forget about your light bulbs-- you will be chasing the problem forever.

--Geoff
You don't have any caution around electricity do you? I'll just wait until you do.
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Old 07-24-2012, 07:56 AM
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Thanks a ton for the responses. I know electrical issues are a beotch.
I don't think I have the balls to short it, id be afraid I'd blow everything up.

Thanks again,
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09 Rhino Sport 700:
UTV Concepts Gauge Cluster, UNI Filter,
HID Headlight Conversion, 2 Kragen HID's,
HotRod Sheave, 16g Grease less OD weights,
Gold spring, MSD, Muzzy's, Innovate LC-1,
Fabtech +6 LT, Fabtech Spindles, Bazzaz ZFI-MX & Z-AFM, J-Lo cage, Crow 5-point
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Old 07-24-2012, 08:11 AM
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Quote: Originally Posted by densercu View Post
Check user the battery box todd I have seen some Picts on the 700s where the wiring rubbed against the frame... Can't remember how but the wire harness was pinched between battery box and frame........
Todd, check this one out. I've heard of this one before, as well. Should be easy to find if it is indeed the problem.

I don't blame you for not wanting to make sparks fly :-) BTW, There is a fair chance of blowing any computer chips on the vehicle when making those sparks fly, as in arc welding with the battery connected.
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Old 07-24-2012, 08:22 AM
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call me
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Old 07-25-2012, 10:44 AM
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Thanks James,

I'll try to call you in the next couple of days.
Life is a little crazy right now.
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09 Rhino Sport 700:
UTV Concepts Gauge Cluster, UNI Filter,
HID Headlight Conversion, 2 Kragen HID's,
HotRod Sheave, 16g Grease less OD weights,
Gold spring, MSD, Muzzy's, Innovate LC-1,
Fabtech +6 LT, Fabtech Spindles, Bazzaz ZFI-MX & Z-AFM, J-Lo cage, Crow 5-point
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Old 07-26-2012, 05:53 PM
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Last time my main fuse blew was because of a bad CDI. It was aftermarket and had something fried inside. Took it out and put the stock one back in..no blow fuse.
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