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Mystery Ground Wire and Blowing 10amp Ignition Fuse on 2003 Kodiak 450

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Old 07-13-2016, 08:48 AM
SpeedyDean's Avatar
2003 Kodiak 450 Speedster
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Default Mystery Ground Wire and Blowing 10amp Ignition Fuse on 2003 Kodiak 450

Recently purchased a 2003 Kodiak 450, and I've been working on a few issues from previous owner. Had it about 3 weeks and I rode it about a dozen times before I blew the first fuse (riding on a trail and everything just turned off). Digital display would not turn on, and thus can't start. I towed it back to house and found that the 10amp ignition fuse was blown. I put new one in, but it immediately blew again. I did some wire searching and looking for bad connections, cleaned some dirt, but didn't really find anything. Put new fuse in and it fired right up (which obviously leads me to believe there may be a bad connection somewhere). This fix lasted about an hour of riding before the fuse blew again. I plan to remove plastics this weekend and go threw all wires again. Are there any wires I should focus on?

The other issue I see, that may be connected to the above problem, is a mystery ground wire coming from the the primary ground wire bolted next to the shift shaft. There is a large gauge ground wire that runs from the battery. There is then a much smaller gauge wire that runs from that same bolt back up under the seat next to the CDI and fuses. This wire is not connected to anything, but has a lug connecter on the other end to connect using a bolt. WHAT is this supposed to be connected to?

Small black ground wire with yellow boot is connected with primary ground wire. The other end is not connected to anything...
 
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