whats blowing me fuse???

Getting annoyed now, and can't get to the bottom of my problem.

Every so often, I go to start it, and the main fuse (60A maxi) pops.
change the fuse, sometimes it will pop another, sometimes it will start and be fine for many more weeks.

So far, I'm on the third starter, presuming the original was the issue, the new was fine for 4 months, than this one has been on since December.
the 2 replacements were used starters the latest from a known source

Replaced relay which failed and ignition switch on Monday.

Checked the wiring last time round around the starter itself, the wiring round the bellhousing was checked and rewrapped last march when I did the clutch and was all ok then, the wrapping is still in tact.

gonna have a good check and try to trace the cable all the way back from switch to starter this eve and check for damage.

otherwise, any other suggestions, cos im at a loss...

I'm loath to presume yet another faulty starter with the exact same issue and go for a new one for it not to be the cause.

Is this maxi link 2, it must be an intermittent short, probably not the starter as you have fitted 2 new ones, perhaps the ign switch. there is a 4 way splice joint I think it is behind the dash which goes to the ign switch, starter relay and a couple of lines to fuses 1 & 2 in the main fuse box. a chafed wire that shorts when the body flexes on startup. ? you may have to remove the loom to inspect.

Have a think tim and work out what can draw the 60a + needed to blow the fuse,

As for the ignition I would imagine this is low amps, the the starter is switched from a smaller exciter wire, I don't think that would blow the fuse,

It could be the feed to the ing switch which is from the FL also the supply wire to the starter relay or fuse 1 or 2 in the main fuse box a short on any of these wires would blow the 60a FL ,not seen one before but could even be the ign switch its self shorting too earth.

cheers owl, will have a nosey for that splice.
It only does it when i "activate" the starter so was thinking it must be somthing on that line, but you mentioned body flex (so i thought engine movement too)
Ignition switch is new too, so pretty much all thats left is a wiring issue.
didn't get to trace the cable last night, with the horrid wind and rain so still got that to do.
it being an intermittent fault doesnt help either

pita intermittent faults

considered putting an insulation tester on it and trying to make the fault less intermittent to aid locating?
wouldn't be the first time i've swapped a fuse out for a circuit breaker to aid diagnostics

Was looking for one actually, you can get them for "normal" blade fuses (ie up to 30A), but not for maxi fuses it seams.

Currently said fuse is 2 bits of 30A fuse wire, got fed up of maxi fuses at a pound a pop (excuse the pun)

yknow, never thought of putting me insulation tester on it...

timtheenchanteruk said:

Was looking for one actually, you can get them for "normal" blade fuses (ie up to 30A), but not for maxi fuses it seams.

Currently said fuse is 2 bits of 30A fuse wire, got fed up of maxi fuses at a pound a pop (excuse the pun)

yknow, never thought of putting me insulation tester on it...

Click to expand...

may be worth disconnecting radio and cb.
what ecu's are on it?

Would do that anyway
nothing else with an ECU/electronics in it, only other bit of electronics is the "smart" relay for the towbar, easy enuff to disconnect that too.

dont fancy frying owt accidentally. will give it a look this weekend.

you got yer disco back together yet? still need to do me a-frame, will be after 1/2 term tho.

yeah, disco back on road!
shop available as and when, just give us a shout.
no expected epics due in, but that's not to say one wont just turn up.......

I had a similar problem. Every time I used the indicators it would blow the fuses by the gear stick and a variety under the seat. I gave up trying to sort the problem and gave it to an auto electrician. All the town in electrics needed replacing, a few switches needed replacing and he had to do a load of rewiring behind the dash where it had burnt out a control box. It took me a few weeks before I gave up. He charged me £200 and had it done in a week, easier and alot less stress.

Just a thought tim, everything goes through the hazard switch on a fender, if you want try se put with mine and see if it still happens,