Return to biking and Diversion 900 problem

victorludorum · L Plate Warrior Joined: 12 Apr 2021 Karma :

Hello!

After having a break from riding when i sold my ZRX1200, I've jumped back in, but with a cheap and hopefully solid Diversion 900. I'm not looking for too many thrills, but just a comfortable ride to get me out and about to do a bit of tourism (living in France). The bike has only done 32,000 km; it's a bit tatty, but nothing serious. It runs well, but it does seem to be blowing the 'signal' fuse regularly. I've taken a bit of the plastic off today and will look a bit further this weekend. The only clue that I have is that it happens when the fuel level is low, so i'm wondering if it's something to do with the level sensor. The fuel gauges seem to have a bad rep on these bikes, but could a level sensor be causing a 20amp fuse to blow?
Cheers all Wink

Gary.

jaffa90 · World Chat Champion Joined: 06 Apr 2016 Karma :

Why not just unplug / disconnect the level sensor but make sure the live feed is insulated.

DUCAUDI · World Chat Champion Joined: 17 May 2019 Karma :

Has the bike got any additional electrical items (extra spot lights, a phone charger or heated grips etc.) on it that might be running off that circuit? Probably a bit of a bodge but try putting a 25amp fuse in there or maybe even a 30amp. Not actually fixing the cause, just avoiding the symptoms. While most people will advise against allowing more amperage through a circuit than it was designed for, most are designed to take around twice the stated amperage before the wiring starts getting anywhere near warm. So 20amp to 25amp, maybe even 30amp, should be no problem.
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victorludorum · L Plate Warrior Joined: 12 Apr 2021 Karma :

Nothing has been added to the bike at all, so the circuit should be as it left the factory. I'm going to take the tank off this weekend and see how things look. Cheers all Wink

Islander · World Chat Champion Joined: 05 Aug 2012 Karma :

Tdibs · Traffic Copper Joined: 16 Jan 2015 Karma :

Ive been through the same on the 600, chasing a blowing fuse on the signal circuit. Have a look at the wiring diagram, on the 600 at least its feeding the indicators and the neutral light and maybe 1 more feed. Have a bunch of fuses ready and slowly eliminate each item by unplugging them until you find the cause. Also worth wiggling the bars and the loom it goes into to see if you can cause it to pop in a certain spot.

For me, it was a short around the headstock in that circuit, obviously for you, it could be anywhere in that circuit.
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jaffa90 · World Chat Champion Joined: 06 Apr 2016 Karma :

Islander · World Chat Champion Joined: 05 Aug 2012 Karma :

victorludorum · L Plate Warrior Joined: 12 Apr 2021 Karma :

I played around with it at the weekend and saw that the fuel level sensor has a plug connector just underneath, so i disconnected that and the fuse is not blowing now. I filled up the tank and took it out for a run and so far it's ok. The fuel sensor could be a red herring of course, but I'm pretty confident it's not. Fingers crossed anyway!

Cheers for all the input; i appreciate it Wink

UncleFester · World Chat Champion Joined: 30 Jun 2013 Karma :

My guess it would be when something in the level sensor activates and then something in the loom wiring could be shorting.

So it's worth checking the wiring that runs from that plug back through the loom.
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Module 1 and 2 passed - October 2014. Happy owner of a 2017 Z1000SX, ex owner of a YBR125 / CB500 / VFR800.