Hiya guys, sorry but im in desperate need of a bit of advice. 3 years ago we tried and failed when making an attempt to reach Mongolia. All has going well and we wee making good ground after a 900 odd km ride yesterday until today and wow did things go wrong.
My Tenere mysteriously died and would not restart
So we checked over a few things but ultimately we found the fuel pump wasnt getting juice as it had blown its fuse.
We replaced said fuse and carried on into some beautiful scenery before pulling in for some petrol, whenId went to leave, cranked over but wouldn't start, wouldnt you know it, the same fuse.
so clearly theres a short somewhere in the system, we've pulled the tank and looked for damaged wires in the loom, but I suspect the ignition barrel is the culprit, this is because
A) the fuse blows when ignition is switched to live
My barrel is free to vibrate as only one bolt holds it in place after somebody kindly broke his steering lock
now we can try to get the barrel removed and checked (it's got security shear off bolts on so needs cutting and cold chiselling)
but we got this far by basically bridging the fuseway with wire (we tried the double amperage fuse 20 instead of 10 and it also blew) clearly its not perfect but
realistically when is this arrangement going to set fire to my bum? myself and my mate may be parting company in the morning and if he heads all the way from here towards the schengen countries (currently in Kazan Russia) should I try to sort in Moscow, we did the bridging thing partly because there was no alternative and also I figured if the short was intermittent the wire would never get so excited for long enough to overheat but im not a competent auto electrician
Can we just wire the fuel pump directly to the battery with an inline switch and continue?
what would have enough amperage in the ignition barrel to blow the 20 amp fuse if thats the highest fuse rating in the fusebox?
On the fuel pump, there is 2 plugs, 1 green 1 white. I guess 1 is for the fuel sender and the other is for the fuel pump. does any know which is which?
Also which colour wire is positive and negative.
please share these questions and post with anyone who might be able to offer some help! basically I needs to decide if its the end of his trip (new ignition set is �1200 from Yamaha + shipping + import duty +accomodations during shipping and clearance so not an option...I really dont want to cut the trip short as I have pretty given up my life back home for another crack at this) by the end of the night
thanks in advance

HI Madbloke, sorry to hear of your woes.

I need a bit of info, the fuse that is blowing, can you see the colour of the wire. so i can work out from the diagram i have as to what could be wrong, may not be the switch

as for the fuel pump, the feed is a red /blue according to the diagam, black's the earth

the tenere had a problem in two areas regarding chafing wiring resulting in shorted out electrics

one was, with the seat removed an shiny allen headed bolt rubbed through the loom, rh frame tube. the loom is tight in this area and fastened with cable ties. i believe Darren 'gulg' experienced the fault

another was under the tank iirc going to the injector
http://www.xt660.com/attachment.php?...8&d=1282659240
info http://www.xt660.com/attachment.php?...8&d=1282659240

personally a good look at the loom to see if any rub through s have occured, you will have to remove a few components and the odd cable tie.

let us know of the colour of the fuse wire and get checking that loom!

all the best, bernard

Hi, I'm posting on eds behalf, don't know the colour of the fuse wire as can't see behind the fusebox but It's the fused circuit for the fuel pump so if anyone has a wiring diagram perhaps they can advise, I spotted that bit of the loom as tight by the Allen bolt, I've pulled the insulating tape and looked for breaks or damage but it all seemed fine?

THANKS ALL!

it was a short across the frame where the loom was badly positioned from new, couldn't find it yesterday on the side of the federal highway in the rain, 28c and sunshine today and I made a workshop in the McDonald's car park made it a lot easier with all your help, so looks like my buddy will follow me east towards lake baikal

great news!

have a good one!

Brilliant use of the forum, fantastic result,great to hear you can now continue with your trip,all the best.