[MonoJoker]

Hi All, recently bought an 06 and it's been going well for a month or so but suddenly when riding offroad one afternoon it started to run rough, lost power and I heard a buzzing from the front relay (behind the headlight). By removing that relay I was able to keep riding (bike ran fine just had to kickstart it). When I got it home I found the starter relay fuse is blown. Checked around the headlight, exposed wiring, etc no obvious shorts, etc.

So I replaced the fuse, put the relay back in, started it up and it ran fine. I rode is slowly around the yard with no issue. Then I parked it back in the shed, left it idling, pulled on wires, poked and prodded, engaged brake, front and rear, turned key off, restarted, trying to make it blow the fuse again. After a while of idling I noticed the tacho "bar" started to flash - which is the first thing I noticed the day I had the original issue. Checked the ignition relay fuse, still intact. Went for a dirt ride on the weekend and it ran poorly (same as before) and then a few minutes in, the relay started buzzing again and when I checked the fuse it was blown.

I've now pulled the seat and tank off, removed the battery and traced all the wires I can around the bike, checked where they contact the frame, etc but nothing seems to be shorting anywhere. Is there anything obvious I can check or something notorious before I admit defeat and take it to a bike shop?

Thanks.

[JimDirt]

Welcome to the site !!

Sorry for a delayed reply .... I have been busy , and I figured someone would have come up with something by now ........

Not sure where you are located (states or abroad) , as the wiring of each is completely different , so that would make a difference in diagnosing .......

If it is a U.S. based bike that was Dual Sported/converted for street use , I would guess to check the dual sport addition for any connection , bad or missing or back feeding ground , or any other loose or possible wiring issue , if it is a add-on and it is not wrapped , it may be that somewhere within the wiring for it , there is a wire worn bare and when going off-road where you are bouncing around , unlike when street riding (again .... assuming since you mentioned Brake Light , that this has a Dual Sport Conversion of some kind ...either that or just a Brake Light Kit) where it is smooth riding and no issues seem to be present if I am understanding correctly , and since (in the U.S.) the Starter Relay is located under the seat near the battery and not anywhere near the headlight , so this concerns me .... since there is nothing behind the headlight to do with starting the bike ..... So this makes me think this is a aftermarket item ....

I can post a Wiring Diagram of a U.S. model from my Factory Service Manual .... but if it is a Euro bike , then I am afraid you will have to search locally for a diagram , or Google