My wife’s 300EX started to blow fuses this weekend. Seems to happen after you start it, put it in gear and let out the clutch. Machine goes totally dead. When we got it back to camp I took all the plastic and gas tank off and started to look for wire rub troughs. Now the 300EX is a 1997 but my wife only ride two or three times a year. I would guess it still has well under 100 hours on the bike. Cleaned up could still pass as new. I found nothing wrong with the wiring harness. So we went out again and on a 30-mile ride it only blew the fuse once. I hope there is a common problem that blows this fuse. If not I am going to totally pull the harness off and anything else electrical. Hopefully I will find what is giving me this problem.

 

Not sure about the 300, but on the 400 the fused circuit only covers the headlights, starter, and neutral light. With the fuse blown, I can push start it and still ride all day. But you say it dies when the fuse blows, or does it just not restart when you turn it off????

 

The motor will die to. I did not try to pull start it. The fuse feeds everything exept the starter. When the fuse blows the motor will stop/stall. The bike is totaly dead after that.

 

I tried this on a 300 last night. While the bike was running, I pulled the fuse out...nothing happened. The bike kept running, the lights kept working, the neutral light didn't go out, but the starter did quit working. You could push start it just fine. (Not putting the lights on the fuse is just dumb!!).

So, I don't think the blown fuses is really your primary problem. If the bike quits running, that has nothing to do with the fused circuit (your bikes ignition spark is not on that circuit). Something else is happening, and the blown fuse is secondary to the other problem. Good luck!!