Got a 2004 400ex that is blowing fuses left and right.. Mainly the starter fuse and the fuse for the lights. I'll replace them, ride it for a couple minutes and they will be blown again. Bike isn't running funny just blowing those fuses. Any ideas?

 

check over your wiring...more than likely oyu have a bare wire thats coming in contact with the frame or something shorting it out.

 

My buddies 400ex was doin the same thing, i ealized when he put his new bars on he was pinchin a wire inside the the think that clamps onto the handlebars.
Wreckless

 

My friends Sea Doo was doin that same $hit (sea doo-atv yea i know thier 2 different machines) but anyways he ended up replacing the magnito. So my guess is that your magnito is bad if it's blowing fuses.

 

Just had a 400ex do the same thing last week. It ended up being the headlight sub harness. The blue wire going into the left headlight was worn thru and shorting out on the headlight bulb socket.

Easiest way to find a short is w/ a light bulb. I soldered two wires onto a single filament turn signal bulb, one wire on the bottom where it makes contact w/ the bulb socket and the other wire on the ground of the bulb, then put two flat male terminals on the wires. Put the bulb wires in place of the blown fuse. When you have a short the bulb will be bright when the key is turned on. Start unplugging connectors until the bulb goes out. In my case, when I unlplugged the green 3-pin connector for the headlight sub-harness, the bulb went out and told me the sub harness was the culprit.

 

Yeah I guess I will start by checking for shorts. Its just hard for me to believe that there is a short somewhere, the bike is has very very low hours on it and hasn't had a bolt touched except for to change the oil and adjust the chain. Thanks for the info guys.

 

Hi
Here is what you need to do...trace the 2 wires from the brake light in the rear..They will connect right above the battery...Disconnect them for good and tape up all 4 ends.. You will not have a rear brake light . There is a short somewhere in the harness that has to do with the rear brake light. A honda mechanic told me to do that to my 400ex and I have not blown a fuse since then . ( 2 years)
Doug

 

If you disconnected the tail light wires and now your not blowing fuses, that pretty much tells you thats your problem, correct? Then why wouldn't you fix the wires going to the taillight so you can utilize it instead of just disconnecting it?