2010 Stelvio 30amp fuse blowing

[Rosso Woody]

Just purchased the bike a couple weeks ago...

Having an issue with the bike blowing the main 30 amp fuse coming from the ignition switch. I started the bike to come home and went to put it into gear and the bike just went blank and died. Pulled off the seat and saw the main 30 amp fuse was blown - replaced the fuse and as soon as you turn the switch to the on position, the fuse blows.

Removed all the bodywork last night to get to all the wiring - seems like I have a dead short somewhere. I cleaned all the grounds and battery terminals to make sure everything is good there. Going to try and go through the circuits and see if I can determine the problem but seems like a wire is open to the frame or have a bad ignition switch...not sure.

My bike does not have the fog lights or even the relay installed. Figured this was a good opportunity to take the bike apart and clean all connections and get the wiring straightened up. The PO had all the wires bundled in a mess and zip tied together.

Any help would be appreciated...

[Kiwi_Roy]

Which fuse is it A or B
http://www.thisoldtractor.com/guzzi007/schematics/2008_Stelvio.gif
There was some talk about misfiring on the alternator TEE connector

Do you know if the bike came without spots or did the PO remove them?

Is it possibly related to the Power Outlet?

A Stelvio expert will be along shortly

[canuck1969]

If the bike does not have a relay for the fog lights installed, start with checking the relay holder where the relay would have gone just to make sure something has not come loose.


Then check the wiring to the ignition switch itself.   Check to make sure the harness is not rubbing when the bars are turned and then check the wires to the ignition itself.  If that is clear, then it is going to be a search of every wire coming out of the ignition switch.  Since the 30 amp fuse is constant power, if the short is not at the switch it self, it will be one of the wires it supplies power through when you switch the bike one.  That is pretty much the entire bike lighting system and startup circuits. 

[Kiwi_Roy]

A trick I use for intermittent shorts is to replace the fuse with a headlight bulb

In this case I would disable the ECU and dash, perhaps just the kill switch you don't want it to try and start or power the ECU with < 12 Volts

The headlight bulb will supply enough current to power all the minor loads without lighting up.

Then scratch around in the wiring, as soon as you get a short the headlight bulb will flash allowing you to quickly zoom in on the culprit.

Sometimes I wire both the headlamp filaments in parallel to get more current but I don't think you will need to in this case, the bike's headlight doesn't switch on until the engine is running

[Rosso Woody]

It is the 30 amp B circuit.

I have not checked the rear accessory plug yet. That was going to be my first check then start going through ignition wiring and look for something exposed or grounded to the frame.

Have not heard about anything on the alternator tee issue?

[Rosso Woody]

You can turn the key to the lock position and the parking lights come on with no issue....forgot that in my original post.

\It is not until you turn the key in the on position that the fuse blows.

[Kiwi_Roy]

How many fuses will you blow before you find the short?
My headlight bulb method is so visual, fast and no fuses are harmed in the process.

[WitchCityGuzzi]

Check the harness under the tank. Some of the earlier models had an issue with the harness rubbing and shorting. I think there was a technical update by dealers to correct it, but can't remember for sure now.

[guzzisteve]

Piece of plastic on the gussets by steering head is what that was. I may have it in files.

Got it #2013-001 Tech Bul
Wiring loom comes out of frame by relay block on R/H side

[Rosso Woody]

Piece of plastic on the gussets by steering head is what that was. I may have it in files.

2013-001 looks to be the technical bulletin for the rear shock connecting rod for the 2013
Got it #2013-001 Tech Bul
Wiring loom comes out of frame by relay block on R/H side

[guzzisteve]

You have to remove the fuel tank to see all wiring. I can send you the bulletin if you pm me your e or take to dealer to see if this was taken care of, they have records of what bikes got done under warranty.

[Rosso Woody]

Email sent

I will give the VIN to my local dealer and see what has been done. The rollerization was the big thing with the bike I was worried about.

[guzzisteve]

Same bulletin covers the ECU boot, centerstand, and other stuff.

[Rosso Woody]

Same bulletin covers the ECU boot, centerstand, and other stuff.

Thanks Steve!

Unplugged the ECU connectors and cleaned them - reinstalled and everything works as before. Stopped by my local dealer and he submitted for the two campaigns as showing not completed on my bike for the center stand and the cover for the ECU. My bike does not have the frame piece that needs the rubber piece - maybe that was the early 2009 models. Thanks for help with the technical bulletin...that made me look there first!

Checked my grounds and starter wire when this first happened and everything looked ok there. I am using this as an opportunity to clean all the connectors and get them routed appropriately.

[guzzisteve]

Glad I could help. One advantage of checking w/dealer on campaigns, free stuff that should be done.

[Rosso Woody]

Glad I could help. One advantage of checking w/dealer on campaigns, free stuff that should be done.

Steve...what are your thoughts on dielectric grease after cleaning the connectors?

[guzzisteve]

I'm thinking it's the wrong stuff, I use a little petroleum jelly.

[Zoom Zoom]

Has anybody actually been able to obtain the ECU cover?

Some time ago, I had asked Todd @ MPH to try to get one and he had no luck at the time. I fashioned a cover of sorts on my own but would happily use the correct piece(s) if I could obtain them. ('09 Stelvio.)

John Henry

[guzzisteve]

I installed 5 or 6 of them, see local dealer.  It could be you only get them on the campaign.

Here ya go----http://www.af1racing.com/store/Scripts/prodList.asp

[Zoom Zoom]

I installed 5 or 6 of them, see local dealer.  It could be you only get them on the campaign.

Here ya go----http://www.af1racing.com/store/Scripts/prodList.asp

Humm, tried following that link but it didn't take me to anything that was a cover for the ECU.

John Henry

[Rosso Woody]

I will let you know what my dealer says on the parts as he put my request through yesterday for my recall.

Moto Guzzi #883968 Protection Cod

[Rosso Woody]

http://www.af1racing.com/store/scripts/prodView.asp?idproduct=50260

[Rosso Woody]

I will let you know what my dealer says on the parts as he put my request through yesterday for my recall.

Moto Guzzi #883968 Protection Cod

John,

Had the part in 2 days and installed last night =. Went through all the other wiring and did preventive maintenance while I have every thing apart. Took the opportunity to wire up some LED fog lights while I was in there and found a 1st generation fog light bracket for the beast!

Woody

[Zoom Zoom]

Thanks, I need to get busy and order the ECU condom for mine. For 8 bucks it isn't worth trying to warranty one. Been busy with a few other things more important. Are you able to fit the ECU cover without taking the bike apart?

As for the 1st gen light bracket, I would say you lucked out. I have to believe those are getting hard to find.

John Henry

[Kiwi_Roy]

Did you ever find out where it was shorting out?

I'm sure a lot of others are interested to know.

[Zoom Zoom]

Thanks Steve!

Unplugged the ECU connectors and cleaned them - reinstalled and everything works as before. Stopped by my local dealer and he submitted for the two campaigns as showing not completed on my bike for the center stand and the cover for the ECU. My bike does not have the frame piece that needs the rubber piece - maybe that was the early 2009 models. Thanks for help with the technical bulletin...that made me look there first!

Checked my grounds and starter wire when this first happened and everything looked ok there. I am using this as an opportunity to clean all the connectors and get them routed appropriately.

Roy, this was an earlier post in this thread. Evidently that trouble was sorted. (See underlined above.) Sounds like excessive resistance due to poor connections causing the fuse to blow. Or, there was a partial short and it was inadvertently cleared while cleaning things.

John Henry

[Rosso Woody]

Thanks, I need to get busy and order the ECU condom for mine. For 8 bucks it isn't worth trying to warranty one. Been busy with a few other things more important. Are you able to fit the ECU cover without taking the bike apart?

As for the 1st gen light bracket, I would say you lucked out. I have to believe those are getting hard to find.

John Henry

According to the technical bulletin - you can fit the cover with the plastics still on (Piaggio quotes 15 minutes time fort he dealer to install). I went ahead and did mine while the plastic is off due to cleaning all the other switches and had everything off.

Installed the fog light bracket and fog lights last night and got the brakes flushed...waiting on relay to come for the fog lights. Should be ready to start reinstalling plastics but just wanted to check the circuit before starting to reinstall everything.

[Kiwi_Roy]

Roy, this was an earlier post in this thread. Evidently that trouble was sorted. (See underlined above.) Sounds like excessive resistance due to poor connections causing the fuse to blow. Or, there was a partial short and it was inadvertently cleared while cleaning things.

John Henry

Sorry, I'm not buying that explanation, dirty connections don't cause 50 - 60 Amps which is what it takes for a 30Amp fuse to pop, it takes a hard short to do that.

Could it have been unused wiring for fog lights perhaps?
Like this model has.
http://www.thisoldtractor.com/guzzi007/schematics/2008_Stelvio.gif

David, given the history of the Stelvio fog lights blowing the 30 Amp fuse I suggest it would be a good idea to add a 10 Amp fuse to feed the relay.

There's a lot of important wiring hanging off that one fuse "B" I can see it suddenly going dark with a dead engine.

How come you are adding fog lights, I thought the Stelvio game with this stock?

[Rosso Woody]

1st generation do not come with the fog lights...not even had a relay. I installed LED fog lights not the issues with the stock Hella lights. The later NTX comes with the light...first gen just has the circuits and switches.

Can't explain the short issue other than my dealer had to run separate grounds before from the ecu. There seems to be a problem based on recall. My ecu has been replaced once under warranty to by a previous owner.

[Kiwi_Roy]

So it had the red/white wire to relay 6, was the relay socket already in place.
I think somewhere that wire got in touch with the chassis.

You may never get to the bottom of it but at least if you split the circuit up a bit future shorts will be easier to locate.