There is a short circuit that wasn't caused by the wiring harness but is caused by either something wrongly connected or by a faulty component.
The advice above is good but I suggest you begin by obtaining a wiring diagram and ensure every wire is going to where it is meant to go as a first and very important measure.
The bike probably has a negative ground system so the negative battery post would go to the frame, etc. and a battery positive would go to the starter relay or solenoid.
Thanks for the details, they do help. Is there a way you can disconnect different electrical circuits from the battery? Like Disconnect the lights, horn, or other components then start adding them back until you find the circuit or group of wires that causes the short. Because it seems you have a short somewhere, or something really putting a load on that 30 Amp fuse. So I'd break the circuits down to smaller pieces so that when you reconnect the lights, or starter, or whatever....that the fuse pops and you know the circuit causing the issue. You may have to open engine components like a magneto to isolate the circuits. But it shouldn't cost you anything except time.
SOURCE: 30 amp main fuse blows when the key is turned on.
Can be "nasty problem, for it can mean DEATH, if as you attempt traffic manouvre & it blows !-(As safety precaution , & this TIP would be useful to most all Bikers>Call to friendly POLARIS ATV Dealer & ask for Automatic Re Settable 20 AMP PROTECTOR ( tHIS FITS THE 500 sPORTSMAN A T V & as far back as the 350L 2 Cycle Firebreathing A T V ()Standard Equipment )-Wire that in from POSITIVE Supply on to your loom, & attch its earth ( Negative cable to NEGATIVE > - on Your Battery!--That done, procede to your RecRegulator Unit &Examine Likely "Melting of Delrin (Nyloc, White looking plastic connector plug to terminals of Rectifier/Regulator , Test Output from Alternator., Ensure ALL Eaths have been attended properly, by Unscrewing, & Shining through the Paintwork Refit, tighten & Apply Silicone Sealant ( So that when You "Power Clean" the Motorcycle You wont be "Degrading the EARTHS again!--Now Ride!--If the Loom Loom, near steering head happens to "Short out" The POLARIS Re Settable Fuse Link & Sealed in waterproof covering, will Re Set & then You get chance to further investigate at Your workshop!!Arm yourself with Voltohmyst , or Multimeter OOR mini pointer that can sense Current Flowing, check out ALL Swithes ( Disconnect rear brake light switch & front one by way of unplugging supply leads ( Just possible that You have intermittant short in one of them!--Did You happen to note IF You were turning slightly to Left or Right when Fuse Blew?--Well, look then for "Stress areas for wiring looms, as at Steering Head Stem region, Open the Sheath with Razor Blade & attempt to pull wires apart slightly , then EXAMINE RFOR>bare leads !---With Multimeter You could slowly "ISOLATE" components & IF You had reference to WIRING CHART You then could Painstakingly TRACE EACK LEAD & ENSURE it has no "LEAKAGE "--Best Of Luck & "StayUpright" -Des.
SOURCE: 2000 Grand Voyager blowing the ignition fuse
Was the old fuel pump bad? It might be worth the cost to replace the ignition switch. The wires to the fuel pump would be a second guess if the old pump was bad and burnt the wires before the fuse went. When you eliminated the fuel pump you also eliminated the wires to the pump and it started. Then you replaced the pump, but not the wires. The ignition switch is the other end of the circuit.
SOURCE: 2002 ford escort zx2 negative ground harness
I am about to have the same problem with my 2002 ZX2. My shop called the Ford dealer and they can replace it for $450.00...
seems like an awful lot for a battery cable.
JS
SOURCE: Ignition Fuse blowing Honda Sabre VT1100
YOU ANSWERED YOU"RE OWN QUESTION,SWITCH,AND RELAY,LOL
SOURCE: the horn doesn't blow. at
Your problem is most likely a defective clockspring assembly. This is also called "spiral cable assembly" it is located just under the steering wheel on the steering column and makes the connection between the main wiring harness and the circuits for the air bag and the horn. I cannot give you wire colors because your question did not mention year, make, model, engine size or whether the vehicle is equipped with cruise control or not. (cruise control makes a difference in the clockspring assembly used on your car.)
Anyway, the air bag and steering wheel has to be removed to fix it.
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