Does it only happen when you lights are on? If not, then the problem isn't there, and you don't need to check those circuits. Had the same problem on the 400EX. It was a short in the lights (only happened when lights were on), so it was easy to find.

 

From what I notice, it seems to blow the fuse whenever it feels like it. It doesn't metter if the lights are on or not. Very strange. I'm done for tonight. I have all day tomorrow and that's it. I also have help tomorrow. Some of my buddies I ride with are coming over to help me. Maybe I'm missing something.

 

Start at the wire that exits the fusebox from that fuse. Keep following it. It should be color coded. I would have the key on while I wiggled the harness/wire along it's course. When you wiggle them and the fuse blows, you are close. It's most likely in an area where the harness flexes between the machine's components. Try duplicating the failure while squeezing or wiggling the grip area where the headlight switch is. It might be worth removing the headlamp switch assemble to check for a shorted wire to the bars. Look near the ignition switch also since it controls engine running along with headlamps. As you are exploring this harness, feel for heat at connections too. A lot of resistance can in time cause a fuse to blow. An arcing terminal connection will make noticeable heat. Hope this helps. Pete

 

What's up all...... I finally found my problem. It was the headlight wire but not up front by the switch or the lens. No, it was rubbing up against my rear grab bar, where the wires met the CDI pack. What a pain in the a$$ it was to find. I've been working on it for months. Thank god that's over. I tuned up the machine, and it is running like new. I can't say enough about this site. Thank you all very much for all your input.... I recommend this site to everyone I know who rides. Talk to ya'll soon.

 

Glad ya found it pal! Little **** like that can end up being a big headache.

 

Yo! Whats up Matty? Sorry to correct you bro but it was the 12v + wire that turns the cdi box on when the key switch is turned to the ON position. Oh yeah, by the way YO MAMA!!!!

 

What's up Mikey Kid....... No problem on the correction. If it wasn't for you, I'd still be blowing fuses. You got the skillz and the tools.... You must have learned them from YO MAMA!!!!! Give a kid a HEMI, and he thinks he's a Rockstar!!!!! Later Dude