ECU Fuse Blowing - Kawasaki Versys Forum
 
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post #1 of 6 (permalink) Old 06-27-2019, 12:08 PM Thread Starter
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ECU Fuse Blowing

I have a 2013 Versys 650 with about 25,000 miles. Over the last two weeks I have had two mini 15 amp fuses blow on me. This has never happened before in my almost 3 years owning the bike. Anyone have an idea what could be the cause of blowing this fuse?

Keep the rubber on the road and be safe!
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post #2 of 6 (permalink) Old 06-27-2019, 12:24 PM
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Regulator / Stator Failure

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Originally Posted by jcenter67 View Post
I have a 2013 Versys 650 with about 25,000 miles. Over the last two weeks I have had two mini 15 amp fuses blow on me. This has never happened before in my almost 3 years owning the bike. Anyone have an idea what could be the cause of blowing this fuse?
We had a recent member with exactly that problem, FYI the ECU is close to $1000 new. Any bulbs failing ? You need to follow my stator testing thread ASAP https://www.kawasakiversys.com/forum...eams-dead.html

Vaiders is one of the members with this failure , most major loads are relay driven, the exception is the stick coils, do the stator test first as it is easily accessed, the stick coils you will need to take the tank off https://www.kawasakiversys.com/forum...U+fuse+blowing
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post #3 of 6 (permalink) Old 06-27-2019, 07:34 PM Thread Starter
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No issue with the bulbs on the bike, everything working fine.

Keep the rubber on the road and be safe!
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post #4 of 6 (permalink) Old 06-27-2019, 09:26 PM
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MK-2 Service manual

drawing 16-45 , the stick coils are powered by the ECU, MK-2 and MK-1 bikes have had stick coils crack and fail, I use dielectric grease around the upper seal, which helps to prevent seizing, some members had great difficulty in getting them out. Since you say everything else is OK, I would look there, once you produce a high voltage tracking, it is impossible to get rid of. Remember a spark or arc is hotter than the surface of the sun, it will etch into porcelain. You may have ignition but the primary may be tracking to ground or you could also have shorted primary turns of the stick coils which would eventually cause the ECU fuse to blow .

A second thing to look at is the harness on the right side, near where the clutch cable enters, several have had the tank rubbing on the harness and a bare spot, the stick coils I think enter from the right side harness. While at it look closely at the left side harness, on my 2015 I used something like 6 of the 100 lb wire ties as my harness was so tight I couldn't get the air box out without prying it out and impossible to get back in. FYI the air box is plastic so no worries as to shorts there. The MK-2 which is what yours is, has plenty of wire and it wasn't until the MK-3 came along that Kawasaki started shortening the wire lengths on the bike. My right side front signal wire/ headlight low and high was so tight it rubbed on the center headlight assembly brace, I extended it six inches.

Last edited by onewizard; 06-28-2019 at 10:41 AM.
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post #5 of 6 (permalink) Old 08-04-2019, 06:57 AM Thread Starter
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Had the tank off again yesterday to make sure not rubbing on wires or bare wires, all looked good. I ride about 5 days a week and the ECU fuse has blown 2 times in the last month. If it was the stick coil, would it be fine for a while and then happen again like this?

Keep the rubber on the road and be safe!
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post #6 of 6 (permalink) Old 08-04-2019, 09:15 AM
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Stick Coils

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Originally Posted by jcenter67 View Post
Had the tank off again yesterday to make sure not rubbing on wires or bare wires, all looked good. I ride about 5 days a week and the ECU fuse has blown 2 times in the last month. If it was the stick coil, would it be fine for a while and then happen again like this?
If you had the tank off, why didn't you pull the stick coils, several members have had cracked coils, condensation gets in and shorts out, at least that would have ruled it out. Be aware if you have never had them out, and they are cracked, you may find yourself without the use of the bike until you get them replaced.Also have either dielectric grease available or vaseline. I use a small amount on the fuel bung, also on the rubber upper surface of the stick coil. Never use a abrasive of any kind on the stick coils in a lengthwise manner, this can lead to carbon tracking from the high voltage spark.
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