Fuse keeps blowing

[waterboymvp]

I'm new to the forum, been reading lots of post and there lots of good info on here. I just bought a 96 sportster and I couldnt get any beeps so I checked the fuses and there was two blown, I replaced the 5 amp and that gave me 1 short beep but the 15A fuse (charging system) keeps blowing before I even get a chance to try to start. Can anyone help?

 

[seadoosnipe]

Charging circuit....?

Does it blow when you put it in or does it blow when you push the button to start?

WHen you put the cap on the post, does it give one short beep and no others before the fuse blows?

Need to know at what time the fuse is blowing.......there seems you may have a charging circuit problem. Maybe grounded stator, bad stator or rectifier. So, need to know when the fuse is popping.

One beep normally means that you have the wrong lanyard key. But it's suppose to be a long beep, not a short one.

 

[waterboymvp]

15A fuse blowing

The fuse is blowing when I hit the start button, I had the engine started once for about 10 sec but when I rev the engine it cut off and wont start back up. Now it will only crank for 2 sec at the most

 

[timmyboy76]

disconnect the yellow and red wires from rectifier, than, install fuse, and give a shot again..say its with yellow wires unplugged, and stops pop'n, then you'll need to check the flywheel housing, might be shavings from starter/flywheel grounding it out. If either, igniting coil or charg'n coil bad or both, I have them new if interested

 

[seadoosnipe]

Bummer.....

Bummer, .....I just got home and see your post was answered. :agree: with timmyboy. I use wireless G at work on my laptop and when I read your reply, I tried to post basically what timmyboy did.........I'm just glad you got a reply.

There are also more tests in the manual, so try what timmyboy has suggested, then if you can't localize it, we'lll go from there.:cheers:

 

[waterboymvp]

Fuse stopped blowing blowing

Thanks Timmboy, I did what you said and the fuse didnt blow. I checked the wiring harness going to the magneto housing and found the ground wire loose, I fixed the wire and put the wires back together going to the rectifier and now the fuse does not blow. But the engine still wouldnt turn over, but I disconected the wiring harness going into the magneto housing and the engine cranked like it should. Could this be because of the grindings that you are talking about? And if so can they just be cleaned out?

 

[timmyboy76]

Thanks Timmboy, I did what you said and the fuse didnt blow. I checked the wiring harness going to the magneto housing and found the ground wire loose, I fixed the wire and put the wires back together going to the rectifier and now the fuse does not blow. But the engine still wouldnt turn over, but I disconected the wiring harness going into the magneto housing and the engine cranked like it should. Could this be because of the grindings that you are talking about? And if so can they just be cleaned out?

hey, glad i could help...with your findings, sounds as if, yyou'll need to remove the motor, or at least, somehow, remove the flywheel cover and take shop vac, and get in there, much as you can. Leaning on, the stators' get'n grounded out...:cheers:

 

[waterboymvp]

Stator grounding

Thanks timmyboy I'll work on that tonight and keep you posted

 

[waterboymvp]

Fluid in flywheel cover

Took the flywheel cover off and found grey fluid inside that smells like gas. The flywheel cover was very hard to get off, the two bottom bolts were not tight, I think previous owner(s) had it open before. When I bought the boat it had a little water in the hull from being outside with no boat cover. I tilted the boat and got most of it out. I think when started the boat the water I didnt get out got in the flywheel cover and thats when I started having the problem. Can I take everything apart, clean and dry, put back together or is everything shot?

 

[Seadoopilot]

Can I take everything apart, clean and dry, put back together or is everything shot?

I would say sure , I have seen motors that were under water 9 months before they were stripped and cleaned , with only a few seals replaced

 

[timmyboy76]

depend'n on type of water...salt,:ack:. Had cable from relay to starter that ate itself from the terminal, thought it was the relay, $45 lesson learned. Moral is, wires off stator, might be trashed/on verge of being...

 

[Gunsrunner]

just had to show you how bad they can be and still recover. my stator didn't suvive but the rest did(wire was corroded)

 

[waterboymvp]

Water Flywheel cover

Hey, thanks for the info, Just got my engine out and it looks about the way yours did in the picture. Having trouble getting the flywheel off, any info on that would be great, thank again.

 

[timmyboy76]

exhaust bolts...

hey...use the 3-exhaust manifold bolts, and thread them in about 1/4-3/8 deep into the 3 holes of the flywheel. Then you'll need a steering wheel puller. Get the "jaws to grab the head of the bolts, and turn "threaded pipe" til she pops. It'll get tuff, but she'll pop. Whenremove'n from crank, dont lose also, inspect the woodruff key, if bad, Ace same one, at Ace Hardware...:cheers:

 

[waterboymvp]

Lighting coil

:cheers:I took the flywheel off and found that the lighting coil had came loose from the armiture and broke a wire, hints my short to ground, whoever was in there before me used wrong bolts. The bolts stripped and coil came loose. Got all back together now, she fired right up... Thanks to everyone who helped me figure this thing out. Now just have hope she floats LOL:cheers: