2005 Eiger - I just started blowing my ignition fuse this week. Hadn't had any problems until now. It seemed like it was happening when I turned when taking off but when I put it in reverse today it blew. I have removed plastic molding so I could see wiring harness and checked for pinched wires, bare wires, etc. Didn't see anything. Does anyone have idea(s) of how to isolate this problem. I'm in an Eskimo village just south of the arctic circle; would cost me $1000 to ship it out to a dealer. I could really use some help.
Thanks,
Buckland

 

Some have issues with the ignition switch and some have bad brake switches. See this old thread.
click here
Id start by drying everything out, and getting some dielectic grease to seal up connectors and switches. It could be a pinched wire.
Will it blow the fuse with the motor off? Is it repeatable, can you make it do it everytime?

 

I had a similar problem on my AC400 and my TRV. Both times it ended up being a pinched wire up under the instrument cluster between the starter relay and the ignition switch.

I found both by taking off the plastic sides and taking apart the instrument cluster. Then tracing the wires from the battery through the starter relay to the switch and to where ever they went. I cheated a little by placing a paper clip where the fust was and wiggling the wires until I saw it spark. Not the best way of finding a short but it worked and saved me a $1000 bill sending it to the dealer via air freight.

It may help to have a wiring diagram for your machine.

SJ

 

Hey thanks!
I was working on it again last evening after getting more fuses here. Started it up, put it in low - blew ignition fuse. Replaced the fuse and pushed on the rear brake pedal - blew. I disconnected the wiring to the brake switch and seems to have fixed it. I disassembled the switch and found corrosion and moisture. I'm headed back to school and going to check it again.
What's up with the brake switches? I was looking in the service manual and I can't find where it is even on the same circuit.

 

I think if you look closely at the wiring diagram. You may see that your suzuki has a start in gear feature. I know it is wired into my ignition circut on my AC. I think there is one circut going to a neutral switch, and another going to the brake switch.

That way if you are in neutral the starter works OR if the brake is on it will start.

A short anywhere along that system should cause the fuse to blow.

You may also want to inspect the wiring harness where it goes up the steering column. If your Eiger has a fuel tank up front then you would need to remove it to be able to see the wires better. If your tank is under the rear rack then you would need to remove the plastic up front.

SJ

 

Good going.
When you put the connectors back together, use lots of dielectric grease, to seal and keep water and corrosion out.

 

Thanks for the advise with grease. Now that the problem has been solved, how do I go about removing my topic so people don't use their time sending me more advice. This is a really great site - thanks to all of you for your help!