Question about 2001 Yamaha YZF 600 R thunder cat

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2003 yzf600r 7.5 amp ignition fuse blows. Day after washing and 3 days after replacing CDI. When fuse blows CDI shorts internaly. Why dosnt the fuse protect the CDI and what could be cusing it to happen.

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  • Yamaha Master
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Hi, Kc6hkd for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
YZF600R Forums View topic Please help my Ignition fuse keeps blowing
http://www.r6-forum.com/forums/57-garage-mechanical-help/212794-ignition-fuse-blowing-when-i-turn-bike.html
Yamaha YZF600 YZF600R 1994 2007 Service Repair Manual PDF Download Manuals...
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Posted on Aug 15, 2016

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Posted on Jan 02, 2017

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caroldon
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SOURCE: 2005 Yamaha Kodiak 400 was

Since you have the CDI failure for the second time , it is important that the voltage parameters are checked on the bike charging system.
The CDI is equipped to handle a wide range but if there is any chance of the voltage build up being higher or containing Ac factors out of a poor rectification circuit, the CDI can be effected. So test the inputs.
Now make sure the outputs are also not shorting out, check the ignition system.
If you have made any alterations, it is an areas to recheck so as the CDI is not draining out into the new unit.
The CDI is overheating with a reason and if you have not found any such defects in the bike it will be good to send your olda nd damaged units to CDI service for review. It can be confirmed if this is a manufacturing errors for which you can even get a free replacement. make sure the ground connections are tight as well as the battery leads.

Posted on Oct 18, 2010

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Doesn't start


Hi, Anonymous and the usual suspects are:
1. Fuel tank empty.
2. Fuel supply valve/petcock turned off.
3. Fouled spark plugs.
4. Engine flooded as a result of overuse of the enricher.
5. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
6. Fuel valve/petcock or filter clogged.
7. Fuel line to carburetor or throttle body pinched or kinked.
8. Carburetor float stuck.
9. Fuel injectors clogged.
10. Severely discharged or damaged battery, you need 12.5 volts or better and be able to pass a load test if necessary.
11. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
12. Loose or corroded wire connection at the coil, battery or plug between ignition sensor and module.
Spark plug cables in bad condition and shorting, cable connections loose, or connected to the wrong cylinders.
13. Ignition timing incorrect due to a faulty ignition coil, ignition module or sensors (MAP, CMP, CKP, O2, TPS, ETP, IAC,or BAS).
14. Faulty neutral, clutch lever, or kickstand safety switch.
15. Faulty fuel pump or fuse or relay.
16. Faulty CDI box if applicable.
17. Tilt sensor needs a reset.
18. Security system not disarming alarm needs a reset.
19. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Anonymous and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting / leaking, spark plug cable connections loose, check for spark leakage in the dark.
6. Faulty ignition coil, pick up coil, trigger coil or CDI box testing needs to be checked with an ohmmeter at 70 degrees Fahrenheit
7. Faulty safety switches clutch, kickstand, neutral, off/on etc.
8. Faulty ignition switch.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Tirso and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting / leaking, spark plug cable connections loose, check for spark leakage in the dark.
6. Faulty ignition coil, pick up coil, trigger coil or CDI box testing needs to be checked with an ohmmeter at 70 degrees Fahrenheit
7. Faulty safety switches clutch, kickstand, neutral, off/on etc.
8. Faulty ignition switch.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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1 Answer

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Hi, Anonymous and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting / leaking, spark plug cable connections loose, check for spark leakage in the dark.
6. Faulty ignition coil, pick up coil, trigger coil or CDI box testing needs to be checked with an ohmmeter at 70 degrees Fahrenheit
7. Faulty safety switches clutch, kickstand, neutral, off/on etc.
8. Faulty ignition switch.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Anonymous for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Reggie and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Loose connection at ignition coil or plug between ignition sensor and module.
5. Spark plug cables in bad condition, shorting / leaking, spark plug cable connections loose, check for spark leakage in the dark.
6. Faulty ignition coil, pick up coil, trigger coil or CDI box testing needs to be checked with an ohmmeter at 70 degrees Fahrenheit
7. Faulty safety switches clutch, kickstand, neutral, off/on etc.
8. Faulty ignition switch.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, John and the usual suspects are:
1. Low coolant level.
2. Restricted radiator air flow.
3. Faulty thermostat.
4. Coolant pump or fans inoperative.
5. Vent hose crimped.
6. Air in the coolant and needs bleeding.
7. Engine idling too long or bike moving too slow.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Davesmart41 for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Hi, Gemmaj_p123 what is your ignition fuse doing, if your blowing CDI's then I would look for a short coming from the CDI on it's way to the coils, cracked or worn or chafed wiring for this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
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