i have a 2000 f4 and it died on me while it was driving down the road. it blew the main fuse and continues to blow the fuse after i reconnect the battery, giving me no lights or anything whatsoever. ive tried replacing the starter relay where the main fuse is, and tried disconnecting the tail lights, blinkers, starter, regulator/rectifier, ignition, and gauges all on separate trials just to see if i could get a fuse to not blow. ive also examined every wire to make sure nothing if grounding out or exposed but no luck there. if anyone has any other suggestions that would be awesome. thanks

 

You've eliminated ALL electrical components EXCEPT the battery. You just answered your own question.

 

I tested the battery also. It's still got 12v in it

 

Voltage isn't your problem, though. That's an irellevant measurement.

If you have examined all wires for ground shorts (which must have been a nightmare, as most of the wiring is wrapped in the harness), then you've either got a bad piece of equipment that the wires connect to, and if you've unplugged all other items, then your battery is all that's left.

 

BUT, that's rare. it's wiring diagram time! Get out your service manual. Here's what I see:

Your main fuse is in the starter relay, which you've already replaced, so we know the relay is not at fault. Let's see where power goes after that:

You have 3 wires coming out of the relay: R, G/R and Y/R.

Y/R goes to your starter button.

G/R goes to your ECM, Clutch Diode (in the fuse box), clutch switch (in the left handlebar), neutral switch, guage cluster, and kickstand switch.

R goes to your METER fuse (in the fuse box). We can rule out anything past that point, or the METER fuse would blow way before the MAIN would. R also goes to the R/R and the ignition switch.


SOOOOOOO there you go. Disconnect all those things, and hook them back up one at a time to see where the problem is. It sounds like a big PITA, but actually, it's not, as just about all of that stuff is on connectors that snap in and out.

Use the wiring diagram in the manual to keep track of what you're doing. it looks like a big ****ing mess, but if you just follow the lines with a pen, it's actually really simple and nontechnical.

I made you a picture of what to pull. Its hard to read, but just look at the circles and compare it to your diagram.:

 

so i did what you said. im thinking its the r/r. i heard that its a common problem in my year cbr and i have an older r/r without the fins so ill give that a try and let ya know. thanks for your help

 

im not a mechanic by any means and what i unplugged last time wasnt the r/r but after looking at the diagram i realized where the r/r actually was and after connecting it, it blew the fuse again

 

That's an absolutly feasible problem. When the R\R's fail, they usually melt internally. This can cause a "hot" terminal to touch a grounded point, short, and blow the fuse. I'm going to agree it's the R\R.