I have an 05 CBR 600RR. I recently added a Two Brothers Titanium slip on exhaust, Competition Werkes Fender Eliminator Kit and a Clear Alternatives Integrated Taillight. Looks great, but fuses keep blowing. The digital speedometer will completely turn off and the running light will also go out. The signals continue to work. I drive from the mechanic shop and the fuses blow at different times. Sometimes two days later...sometimes the moment I drive off the lot. I replaced the integrated taillight, but that didn't solve the problem. The mechanic stated the the wires appear to be OK. Clear Alternatives stated that it was not their product that was causing the fuses blowing. I'm now placing the stock taillight back on to see if the fuses will begin to blow. If you have any advice it would be greatly appreciated. Thanks.[:@]

 

1st check your battery if the plugs + and - are hooked right and tight.
if still doesnt work
-remove the plugs or wires of blinkers
-remove/unplug anything you've added to the bike that is useless :P
-put new fuse in the box
-try!
if still doesnt work
-enjoy searching at a malfunction wire that is cut, touching something that it shouldnt, crushed, missing, etc somewhere
-headlight
-speedo
-etc
if still doesnt work
-try using a new battery

 

I was expecting to click on your attachment and see a pic of the taillight but much to my delight it was two fine ladies forced to take a picture with a man cheesing like the first day he got his motorcycle!![sm=Flahssssss.gif] Start from scratch, put your factory taillight on and see if you pop any fuses. Retrace your steps and youll figure it out.

 

Since the fuse/s aren't blowing every time you power up... I'll assume you're wiring is good. If it's random like you said, then I'd guess that one of your add ons are causing a short over time. I always solder and heat/shrink wrap my connections on a bike to make sure there is no possible way for a short/grounding problem. Maybe one of your components has a design/manufacturing flaw and it takes a few bumps before it shorts out. Go back stock and try one modification at a time to see when the fuse/s start to blow.

 

There are only three wiring problems. Opens, shorts and grounds. An open means that the circuit has been interrupted by a broken wire or bad switch. A short is flow directly to ground without a load, such as a wire from the positive side of the battery touching the ground. A ground is similar to a short, but on the ground side. A blown fuse or cooked wiring indicates a short. How do you find it?

Using the wiring diagram, isolate your circuits by disconnecting all the grounds and insulating them (with tape) so they don't make contact. Get a continuity tester, (a self-powered test light, $10 from Sears), and connect the aligator clip to ground and probe your connectors. Any circuit that still has continuity contains the short. Pinched wires can short even though the insulation appears intact.

 

Thanks everyone! I'll continue on my journey of finding a solution. The CBR Forum is AWESOME! I should of joined months ago. Take it easy.