I keep Blowing the Main Fuse...... The headlight causes it.

[56Nomad]

I have an almost new 2003 400EX Honda with very few hours on it.
The first time I tried going for a night ride the lights kept blowing
the 15 amp main fuse (the only fuse)
The lights go out but the
quad stays running. After it is shut down, it will not start until I
replace the main fuse. By the way, the lights stay on for 15 minutes or
so, before they blow the fuse.......... so it is not an immediate short.

We took all the plastic off and looked at the wiring. No damage seen
and the wires all look like new. Nothing touching the frame.

Any thought of bumping up the main fuse to a 20 or 25 amp fuse and
letting the short show up in the wiring?

Any other suggestions to track this problem down or a fix ?

Thanks

[mojoe2878]

your problem is in the light sockets or bulbs. probably a short in one of the wires where it is connected in the light socket where you cant see it. if you put a bigger fuse in it, it will still blow it, the only thing it may do with a bigger fuse is melt the rubber insulation off the shorted wire before it blows the fuse, but you will still have to trace that wire to find the short spot, then replace the whole wire.

[400exdad]

I'd check the switch on the bars. There may be a problem there.

[56Nomad]

Originally posted by 400exdad
I'd check the switch on the bars. There may be a problem there.

400exdad, Thanks for that tip.....

What should I look for in the switch?
Can the switch be tested?

Does anyone have a switch for sale?

yea dude i have the same prob......but my lights are f***ked up so i need a nother light set or i might just get a race fromt and the handlebar lights.

[56Nomad]

The short was in the dimmer switch!

Does anyone have a switch or harness or sale?

Email me if you can help. Thanks.

laselvaduramax@yahoo.com

[400exdad]

Is there any way that you can repair it? Usually the switches are not tied to ground in any way. It would seem that the wires have some way gotten pinched between the small clamp and the handlebars.

Do you have a 56 Nomad?

[56Nomad]

Originally posted by 400exdad
Is there any way that you can repair it? Usually the switches are not tied to ground in any way. It would seem that the wires have some way gotten pinched between the small clamp and the handlebars.

Do you have a 56 Nomad?

I scrutinized the switch and all the wiring in and
around the switch......found no obvious defects.

It is the high beam mode that blows the fuse. I
put a 20 amp circuit breaker in the main fuse
slot and each time I turned the high beams on
the green igition light dimmed, but it did not
blow the circuit breaker as it did with the 15 amp
fuse.

I cut the high beam wire inside the switch control
leaving me only low beams, but that solved the
problem of blowing fuses

I'll still be looking for a replacement switch
harness......

Just sold my hotrod Nomad

[throwinitup]

that's a killer nomad, dude....mad props

[the Z Man]

Mikeracer sold me mine, it went bad at Little Sahara right before our night ride, sometimes timing on these suck... ebay is around 30 bucks... Z.