I have an 01 Warrior I am the original owner of. If you are standing behind the machine, underneath and to the left of the rear bar, there is a fuse holder assembly. For some reason the fuse keeps blowing. It blows at least once every time I ride. I replace it every time with another 10 amp fuse like the book says. The fuse continues to blow. When it does, I lose all lights, electric start, etc. As you know, the warrior does not have a backup pull start. I always keep extra fuses under the seat, because I know it is going to blow at least one, and I do not want to get stranded.

What I want to know is:
1) Does anone have the same problem?
2) How can I prevent this from happening anymore?
3) Can I use a larger fuse, and will it hurt the machine?
4) Why is this happening?
Thanks All....
Any suggestions will be greatly appreciated

 

The old Big Bear I had used to do the same thing- it was abare wire in one of my head lights. My guess is you have a similar problem, a wire grounding somewhere.

 

You need to look at your wiring, you have a bat + wire shorted to ground for one of those circuits, when that happens it is going to blow that fuse. The fuse is there to protect the wiring from catching on fire, do not install a higher amp. fuse. just take your time and look things over real good where the wires run along the frame, and where they go in to the case for like the stator take the cover off and look also look at the light sockets, look at the light switch at handle bars, you will find it just takes time.

 

OK, But what exactley am I looking for? A charred wire?

 

Yes any wire that has the insulation worn off in a spot should also show signs of arcing. Don't overlook light sockets and any switches where the bat.+ wire could be touching ground.

 

Thanks for all your help... Sounds like I have my work cut out for me....

 

I had the same problem a month ago. I have a 2003 warrior, and mine was blowing fuses all the time. I stripped the quad down to almost nothing stripped every bit of tape off of the wiring, only to find that one of the leads coming from the handle bar switches had rubbed on the steering neck. Needless to say there was one bare wire. I started it touched that to the frame and poof blown fuse. taped it all up real good there and no troubles ever since. Hope this helps.

 

Thanks catfish, I will start there. Most people that responded said it would either be the Handle bar switch, or the headlights. I am going to work on it tonight after work. I really appriciate all the responds. This site Rocks!!!!!

 

OK Fellas, It is now Friday night, and I still have not found my problem yet. I've worked on it every day this week after work. I just cannot find this short. To add to things, my battery is now dead. I haven't ran it in awhile, because I've been trying to fix it. I have until tomorrow to fix it because, I will not go an entire weekend w/o riding. We are going on Sunday, and I need this bike running like a top. Any more suggestions?????

 

It maybe close to your battery. Look around all the connections and wiring. Your battery shouldnt drain that fast.