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Discussion Starter #1
New here and can use some help. Neighbor has a 2000 Rancher ES blows main fuse with key off. Problem started when riding, just died, found blown fuse. Rigged up test light to each side of main fuse spades. The only way the light will go out is to disconnect the dash, rectifier and key switch. What do these three things have in common. Or does he have 3 different problems. Ordered a regulator/rectifier. Will swap this out and keep going. The regulator/rectifier looks damaged near the mounting bolts. Thanks in advance.
 

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I hope you ordered an OEM Honda regulator / rectifier because the Chinese copies are not very dependable. So let me try to understand - all three of those things had to be disconnected to keep the fuse from blowing??? I don't have the wiring diagram here but my guess is that some insulation has worn off of a wire thus causing a short to ground.

Or, as you surmise, a short inside the reg /rec has occurred. An interesting test would have been to see what voltages (DC and AC) were making it to the battery with the bike running. Anything much different than 14.5 VDC and anything over a tiny amount of AC would have convicted the reg / rec as faulty. It takes a good 30 dollar or more multimeter to accurately measure small amounts of AC - the cheap meters often struggle here.

Rick
 

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Discussion Starter #3
Yes, all three have to be unplugged for the main 30amp fuse not to blow. The reason I ordered a rectifier is it shows signs of damage. My next step is to open up the wiring harness, but I was hoping not to have do that. Not able to run the bike, pull rope is broken, so no test while running. I have a nice fluke meter ~ $75, the meter is better than my testing skills.
 

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Discussion Starter #4
Ok so with new rectifier plugged in the main 30amp fuse is ok. When the key is turned on the 30amp motor fuse blows. Any ideas? With the motor fuse blown the electric shifter does nothing, everything else seems to work
 

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Hi: Try this remove the Light, Ign., Fan & Acc fuses -- then turn the key on see what happens -- if the 30 amp fuse holds then put one fuse back in at a time see what happens.
 
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Discussion Starter #6
This thing is kicking my butt! Removed all fuses, and now when I install the motor fuse it fails with the key off. The only time the fuse is ok is when the rectifier is unplugged. Checking the wiring diagram the rectifier has nothing to do with the motor fuse
 

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Hi: This bike you are working is a 350? --- If the motor fuse is blown with key off unplug the small connector on the ECU and try again.
 
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