X Challenge blowing Fuse F

Robster

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So, just back from the Hard Alpi Tour on my X Challenge - what a ride!

Had some issues with the XCh blowing Fuse F... pretty much every couple of hours at one point!

It started as I pulled on to the Ferry at Dover and the bike just cut out, engine, lights, display, everything. I thought my trip had come to a sudden end before it had even begun, but a quick Google over breakfast (which suggested I might have stretched a wire to a diagnostic plug against the frame) and special access to the car deck allowed me to swap the fuse and had me going again and I was able to ride off in to France.

As the bike got hot, riding down the Paeage to get the miles done, it would blow the same Fuse F while standing at toll booths, fuel stops etc with the engine running waiting for the others. Then as we went on I'd turn off to let the engine cool for a minute or two at these stops but the bike would blow the fuse as it went through its diagnostics when I turned it back on.

Then, on one occasion it blew as I was riding down the motorway! Wasn't especially hot, hadn't turned the bars or anything. However, with a pocket full of fuses from service stations I eventually made it to the start of the Hard Alpi... where it blew just as I was about to exit Parc Fermé! Not a great start! :blast

Over the course of the rally which took me just over 23 hours I blew a load more fuses – I set off with a bag of 10+ and had just 2 left when I finished. It was a mixture of blowing when hot while standing, blowing when I turned back on after a few minutes off (although it would usually be ok if I left it off for more than half an hour or so), blowing once when I kicked the sidestand up (although that may have been coincidental) and one time it blew in the depths of the night in the middle of nowhere with nobody else around as I was descending a steep trail in the pitch black - engine off, lights off, everything just cut out! Scary!

However, after the Rally and for the next 3 days trail riding and 2 full days back home over some great Alpine passes and a load of dull Paeage it didn't blow a single fuse! :nenau

I'm going to have to strip the big Touratech tank and everything off to give it a proper clean as it's caked in Alpine mud and crud, but does anyone have any ideas where to look initially for what might be causing the issue?

Quite tricky as there wasn't much pattern to when it would blow. My thoughts were that the big TT tank was restricting airflow to maybe the starter relay (which operates off that fuse), the reg/rec or maybe even the ECU under the seat. Then again it may be as simple as a cracked/bared wire that I'd shaken into a position where it was shorting whilst laning before I went away and shook back out of the way whilst doing the HAT!

I've seen this on ADV Rider, but they're talking about a different fuse... possible it's the same cause though?

Any ideas of where to look first would be good to know!
 
Is your fan and associated wiring okay? Only reason I suggest this is if it tended to blow when slow moving or stationary, then those would be the times it would come on.

Other than that, not a clue.
 
My 2007 Xcountry was doing this intermittently, would run OK for days, then blow the fuse. Checked the ignition switch (a known cause) and the full length of the wiring loom front to back. Ignition on and tried to replicate, wiggled and pulled the wires but to no avail :nenau

It seemed, with later investigation, it might have blown the fuse on application of the front brake .... but not consistant :blast

Noticed the rear brake light led's intensity was only half as bright with the use of the front brake lever. Application of the rear brake lever resulted in normal bright intensity.

Put a new front brake micro switch on, resulting in full intensity brightness of the rear brake light .... and the fuse blowing, to date, several months later, several thousands of miles, has not happened again :eek:

Now keeping my fingers crossed ;)

Might not help but then again might be a starting point for ya :thumby:

:beerjug:
 
Is your fan and associated wiring okay? Only reason I suggest this is if it tended to blow when slow moving or stationary, then those would be the times it would come on.

Other than that, not a clue.

Fan appears to be coming on as normal (ie quite a lot when going slow) cooling the bike then going off. As far as I remember it never blew with the fan coming on or going off.
 
My 2007 Xcountry was doing this intermittently, would run OK for days, then blow the fuse. Checked the ignition switch (a known cause) and the full length of the wiring loom front to back. Ignition on and tried to replicate, wiggled and pulled the wires but to no avail :nenau

It seemed, with later investigation, it might have blown the fuse on application of the front brake .... but not consistant :blast

Noticed the rear brake light led's intensity was only half as bright with the use of the front brake lever. Application of the rear brake lever resulted in normal bright intensity.

Put a new front brake micro switch on, resulting in full intensity brightness of the rear brake light .... and the fuse blowing, to date, several months later, several thousands of miles, has not happened again :eek:

Now keeping my fingers crossed ;)

Might not help but then again might be a starting point for ya :thumby:

:beerjug:


Yup, ignition switch is on the list of things to check when I strip it all down.

Good info re the brake light switch too, deffo worth a check.

Really strange/annoying as I've had the bike for 2 years and it's never missed a beat on longish journeys and some fairly energetic green laning! Even stranger that it appears to have sorted itself out...but obviously I can't trust it now until I've found the cause! Grrrr, electrical gremlins are the worst!
 
Really strange/annoying as I've had the bike for 2 years and it's never missed a beat on longish journeys and some fairly energetic green laning! Even stranger that it appears to have sorted itself out...but obviously I can't trust it now until I've found the cause! Grrrr, electrical gremlins are the worst!

Ha ha :thumb

The trouble is I haven't for sure found the cause :nenau

I wished it would have blown the feckin' fuse every time I put a new one in, and give me a chance to find the cause, but no, it wasn't that simple. Put a new fuse in and she'd be OK for a day or two, a week or two :blast

But not happened since replacing the front brake light switch ....

Hey ho on we go ...

:beerjug:

Edit .... ABS model? A dealer technician pal steered me towards where the wiring harness is tie wrapped to the ABS unit at the rear of the cylinder. Very tight and can cause a break in the rather cheap quality wiring harness. I cut mine free & waggled it but couldn't blow the fuse :nenau
 
Edit .... ABS model? A dealer technician pal steered me towards where the wiring harness is tie wrapped to the ABS unit at the rear of the cylinder. Very tight and can cause a break in the rather cheap quality wiring harness. I cut mine free & waggled it but couldn't blow the fuse :nenau

Nope... non ABS. I thought it would preclude certain problems! :)
 
Could be the wiring around the head stock area,

Always the first place to go for. Although the G650X bikes are great machines one of the corners cut in manufacture was the quality of the wiring .... brittle :eek:

I even had the main wire from the battery terminal fracture ... cut out suddenly at 80mph overtaking about six cars on a long straight road :eek:

The steering head was my first port of call ... waggling and moving the wires with the ignition on, trying to blow the fuse ... zilch, nowt :nenau

:beerjug:
 
Water on the starter solenoid blew my F fuse or the ignition barrel pins lost everything once
Soon fixed though
 
Water on the starter solenoid blew my F fuse or the ignition barrel pins lost everything once
Soon fixed though

I had problems with my starter solenoid- the bike was forever blowing fuses. Replaced and no problems since. Stripped the old solenoid and couldn't see any issues with it though?
 
I had problems with my starter solenoid- the bike was forever blowing fuses. Replaced and no problems since. Stripped the old solenoid and couldn't see any issues with it though?

Sounds like a potential culprit – I wondered if the big TT tank was somehow restricting airflow and causing the solenoid to overheat hence the fuse popping unless I let the bike cool for half an hour or more. Good place to start though, cheers.

By the way... was that you pulling in to the finish of the Hard Alpi just as I was leaving?! Saw a UK XChallenge arriving with a F650 and something else that escapes me due to the fatigue! :)
 
Sounds like a potential culprit – I wondered if the big TT tank was somehow restricting airflow and causing the solenoid to overheat hence the fuse popping unless I let the bike cool for half an hour or more. Good place to start though, cheers.

By the way... was that you pulling in to the finish of the Hard Alpi just as I was leaving?! Saw a UK XChallenge arriving with a F650 and something else that escapes me due to the fatigue! :)

Yes, that sounds like us, i was on my black and white XC, Stan was on the F650 and Drog was riding his KTM 690.

Did you stay on to ride the "extreme"?
 
Yes, that sounds like us, i was on my black and white XC, Stan was on the F650 and Drog was riding his KTM 690.

Did you stay on to ride the "extreme"?

Nah, I was fairly well "spent" by the finish and just glad to be there – had a hotel booked about 500yards from the finish in Sestriere so after a shower and a couple of celebratory beers I was pretty much nodding off into my pasta!

Camped for another 3 nights afterwards down the valley outside of Briançon and rode a load more trails - did the Stella route again, Mont Jafferau, Fort du Gondran etc etc

Awesome event, thoroughly enjoyed the challenge – need to go back and spend 3 leisurely days riding the route again though to see what we missed in the night! :)
 
Not had chance to even wash the bike yet, that's on the cards for Saturday, but will post back what I find - thanks for the suggestions.

Set of pics of our 2014 Hard Alpi Tour if anyone's interested!
 
So, was having a quick look over the bike on Wednesday night before an MOT on Thursday and I thought I had found the smoking gun!

I noticed the (aftermarket R&G LED) numberplate light wasn't lit and, on investigation, the wires at the back had snapped off where they entered the loom under the tailpiece. After some fiddling about I ascertained the light wasn't working at all even when reconnected so figured it must've shorted and burnt out. Hooked up another bulb as a test and there was light. Touched the 2 bike-side wires together and heard the familiar click of a fuse popping and thought I had found the issue.

Unfortunately, it had blown another fuse, and not Fuse F! D'oh!


So, it passed the MOT anyway without a numberplate light (does it need one?) and it's now being slowly disassembled in my garage. So far, there's nothing obviously exposed or stretched against the headstock.

I pulled out the Idle Actuator while I was at it and it was filthy! Cleaned that up so hopefully that'll sort my hot-start issue.

The Starter relay looked a bit corroded so that's a potential place to investigate further. I pulled off the terminals, cleaned them up and greased them anyway. Maybe worth replacing the whole thing if the problem reappears, but the corrosion suggests that there's been water trapped in there for some time at least.

Nothing loose or unplugged behind the headlight. I did have a thought thought, the indicators are on Fuse F and I wondered if some water ingress into the rear indicators might have shorted something out there and caused the problem until it eventually evaporated. The inside of the lenses are very dirty so there's certainly been some water in there.

More things to go through yet anyway, I guess I'll have to keep going until I find something :nenau
 


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