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Pcmodeler
Posted on Thursday, September 12, 2019 - 05:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

OK. Searching has shown me that this is a common problem with the XB's. I've done some of the troubleshooting steps. The fuse blows when I have the ignition relay in place. It does not when I remove the relay. I have swapped all the relays around so I'm fairly certain the relay isn't the issue. I've also seen where the #77 connector to the voltage regulator can be removed to diagnose. Which of the connectors down by the front sprocket is the proper connector? It's the one with just the red and black wire, correct? If so, I have disconnected that and the fuses still blow. So I assume that rules out the voltage regulator? Does that just leave me with hunting down a short somewhere?
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Livers
Posted on Thursday, September 12, 2019 - 06:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Unplug your headlights and test again.
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1_mike
Posted on Friday, September 13, 2019 - 10:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Unplug the fuel pump harness and install another fuse, turn the key.
When the wiring on my pump decided to chaff and short on the bracket, the first thing to go was the Ign, fuse.

Remove fuel pump, fix open wire in your own particular manor, make sure it won't happen again (as in deburr sharp edges), reinstall pump and off you go.

Mike
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Pcmodeler
Posted on Friday, September 13, 2019 - 11:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Will try the headlights.

Not the fuel pump. Actually thought it was the fuel pump in the first place and that's been replaced. Also replaced the coil pack.
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1_mike
Posted on Friday, September 13, 2019 - 12:42 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Pc -

As a last check...just because the pump's been replaced, doesn't mean a wire hasn't been chaffed since then..!

Unless you've already done some protection so it won't happen like many have.

Mike
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Akbuell
Posted on Friday, September 13, 2019 - 12:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

This will sound weird, but work with me here.

Had the same issue with my X-1. A brother from a different mother, as it were. The culprit turned out to be the speed sensor, a fair number of fuses later. The power wire to the speed sensor had shorted out to the ground wire, where the harness goes into the sensor itself.

I would try unplugging stuff one at a time. Headlights, then fuel pump, then speed sensor.

Hope this helps, and please let us know what you find. Dave
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Audiowize
Posted on Friday, September 13, 2019 - 02:03 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The proper course of debugging is to unload everything that fuse powers, then add each component back one at a time until you figure out what's causing the problem.

If you take everything off and the fuse still blows, that's a good indication that the wiring harness has an issue.

It is painful to look at the wiring diagram, but what comes after the relay is:

ECM
Data Link Port
Injectors
Coil
Fuel Pump

To clarify, I am presuming that with the key off, you can plug the relay in and the fuse holds?
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Tpehak
Posted on Friday, September 13, 2019 - 02:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Download service manual for your motorcycle model year. There is electric diagram in service manual. You can find the fuse blows and find the wires and units may cause the issue on the diagram. You will also need tester to check the wires and units. Shortage can be between wires, between wire and ground or inside bad unit.

You also can download electrical manual for you motorcycle year, electrical manual has detail instructions how to troubleshoot blowing fuses and bad units.

I would use just diagram from service manual to figure out how current flows thru the fuse and check circuits related to this fuse with tester.

(Message edited by Tpehak on September 13, 2019)
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Rsh
Posted on Saturday, October 05, 2019 - 03:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

On 2003 XB9's a bad speed sensor will cause the ignition fuse to blow. Try disconnecting the speed sensor and see if that is the problem.
There was an updated sensor that cured that issue. That's what worked for me.
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