I've got a viper 50 and a 90 and both do the same thing. Both had no key switch and not running when I got them. Got a new battery and key switch and as soon as I turn key the 7.5amp. Fuse blows. I've disconnected everything except key switch and it still blows fuse. Took out harness to check and it looks good. Any help would be great, these things are killing me! Thanks

 

You have bought the wrong switch or wired it in wrong. I assume it is a four wire switch, one wire goes from fuse, one to horn etc, one is earthed and one comes from CDI, via stop switch. If you wire it so the live from fuse connects to the earth when you switch on, it is going to blow the fuse.

 

you may be right, I got 2 off of e Bay that have the right connector and says it's for my 4 wheeler. The wire colors are different, so Idk if I can just move the wires to the connector and see, but I'd be guessing because they still are different colors.

 

If you guess, you could end up feeding the CDI kill wire with 12v positive, and blow it. According to the wiring diagram, black/white goes to kill switch, red from fuse, brown to horn, start button circuit etc, and black from earth. When on the switch connects black to black/white and red to brown. Note this is unusual for Chinese bikes, so your non genuine switch may not work this way, (though a lot of Hondas do.)

 

Well, I just ordered a oem ignition, oem voltage regulator and a oem starter relay. Once they come in I'll check them one by one and hope I one works. I will post as soon as I find out. I'm not going to take a chance with the other key switch. Thank you

 

The factory ignition switch fixed it! I got power without blowing a fuse, but no start or click. Swapped out the starter relay and it started. Now just a fluids check and a carb clean and it should be good to go. Thanks for the help, I can't believe they sell aftermarket ignition switches that are not up to spec. How the hell do they stay in business.

 

My sons 90r keeps blowing a fuse a few second to minutes after starting. I don’t see any noticeable wire damage and everything is original. It had been working perfectly and just started doing this. Any suggestions or help would be great, thanks

 

Check all the positive wires from fuse through switch to horn, starter switch, light switch, rectifier, etc, for bare wires shorting to earth. Most likely to be internal fault in switch or rectifier, but these are difficult to check for. Rectifiers tend to blow fuses with ignition off as well as on, though.