I have a 04 rancher 350 that when I start the bike it will run for a bit then the 15a light fuse will blow and 4 wheeler will die. The lights aren't turned on and I traced the wires to look for a bare one and didn't find any. I have not really ridden the bike much in the last 5 years because of deployments to Iraq I would say about 50 hours tops. please help me with this headache.

 

The starter and lights are on the fused circuit. On all my Hondas, once they are running you can pull the fuse out and it will not kill the engine....so you have something weird going on if your fuse blows and the engine dies at the same time.

 

Has any work been done on the machine recently?

 

well I just asked my dad what it was doing with him when he rode it while i was gone and he said it was blowing the fuse trying to start. I think it might have died with me after it cranked cause it just hadn't ran in a while. What do I do to fix the problem if it is the wire to the starter or lights?

 

It has a pull starter....so at least it is rideable (without lights) while you sort out the problem!

Only thing you can do, is trace out the lines and look for a short somewhere. Service manual wiring diagrams and a voltmeter will help.

I had a short once on my 400EX, and it came down to the insulation getting worn off a wire where it got squezed between the plastic and the frame.

 

well I have the bike down with out its plastic but still cant find the bad wire. My dad said that it just started blowing fuses after he jumped off a generator with it one time. do you know if it could have shorted something out and if so what would it be. thanks

 

So does it only blow the fuse when you hit the start button? Could have fried the winding in the selenoid.

This generator he jumped it with, do you mean an arc welder?

 

It is currently blowing the fuse as soon as I turn the key one but it has let me start it a time or two.

 

It was just a regular generator to run his 5th wheel.

 

i would try and disconect starter wires and tape them up then use rope to start and see if fuse blows .( if it was a ninja zx12 id say it was ur fuel pump dang kawi.)