2010 KTM 530 EXC Blown Starter Fuse

Ok 2010 530 EXC 65hrs

About 5 rides ago the the fuse blew while out riding (did not notice until I shut it off and tried to start). Replaced it with the spare and no problems.



2 rides ago same thing happed after a couple of hours riding. I was paying attention and noticed it happed after I started the bike.



Now yesterday almost at the end of the day same thing. I thought it could be a bad cell in the battery (Nope 12.72 volts) or starter relay getting dirty (have to check out current draw) or voltage regulator. I have already checked out the wiring and found no chaffed wires/shorts or ground issues.



After reading a post on TT. I am now suspecting the ignition swith as this could explain the intermitnent problem I am having. Any one else have this issue?

Well after a bunch of testing and hair pulling I found it.

A little back ground here (no pun intended ) . When I first got my bike I removed the emissions junk and the horn. I wrapped the connectors in electical tape and zip tied to wire bundle.

So what I have pieced together is this. The zip tied horn harness over time vibrated loose which allowed slack by the front fork steering stop bolt on the frame. At some point the harness was pinched against the bolt. The black jacket was not cut open but scuffed a little. What happened inside was the insulation on two wires were smashed and were shorting together randomly.

Doh I am my own worst enemy. Only took me two days to find it........

That is just what I would of suggested.