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Samurai keeps blowing ignition fuse

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Offline robbin

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Samurai keeps blowing ignition fuse
« on: October 01, 2009, 02:07:56 PM »
I have an '87 Samurai that blows ignition fuse every time the battery cable is removed, and sometimes when just normally driving.
I have replaced alternator and all fuses and fuseable links. When I put a new fuse in it will start and run good, but sometimes after it runs for awhile the fuse will blow and the engine will die.
Any time the battery cable is disconnected if the engine is running or not, it will blow the ignition fuse.

Does anybody have any ideas?
-Bob

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Offline john1974

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Re: Samurai keeps blowing ignition fuse
« Reply #1 on: October 01, 2009, 02:28:17 PM »
Friend of mine had this issue and it was a fuel pump going bad in his fuel injected samurai.  Since the 87 is carbed its got to be something elec because it has a mechanical fuel pump. 

I wonder if its the ecu.
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Offline zukimoo

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Re: Samurai keeps blowing ignition fuse
« Reply #2 on: October 01, 2009, 02:42:07 PM »
check all the wires that are at the carb. Look for worn spots or kinked wires. My brothers zuke did the same thing and it was a wire at the carb. GEt a wiring diagram and trace the wire that is linked to that fuse and then look at those areas. make sure to put the right size fuse and not be tempted to put a stronger one. It's not worth it to loose the whole zuke.

You can buy a "breaker" style fuse at the garages that specialise in auto eletrics or even the auto parts store. This will make it easy to turn the fuse back on....rather than waste a fuse each time.
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Offline Uncivilized

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Re: Samurai keeps blowing ignition fuse
« Reply #3 on: October 01, 2009, 05:26:21 PM »
You can buy a "breaker" style fuse at the garages that specialise in auto eletrics or even the auto parts store. This will make it easy to turn the fuse back on....rather than waste a fuse each time.
I have one of those in my Tracker, it blows the IGN fuse whenever I have the key on for a while while the engine is off.
It's a Cole Hersee, cost about $8 - good to help you find the actual problem without wasting fuses

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Offline zuksofhazzard

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Re: Samurai keeps blowing ignition fuse
« Reply #4 on: October 02, 2009, 07:29:18 AM »
I'd start checking for Good Grounds.

I had trouble in an EFI Tracker, kept popping the Ignition Fuse. I had a Bad Ground from the Disty to the Firewall.

Suzuki Vehicles are particular about Grounds or Ground Wires.

Make sure Everything is Grounded.  ;)

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Offline john1974

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Re: Samurai keeps blowing ignition fuse
« Reply #5 on: October 02, 2009, 09:47:02 AM »
Yep, grounds are key to samurais.
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Offline ebewley

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Re: Samurai keeps blowing ignition fuse
« Reply #6 on: October 02, 2009, 09:51:10 AM »
I would look at your ignition switch in the column. Disconnect it from the harness and test the leads to ground for continuity. Insert key and 'wiggle' it around while your testing to see if the switch goes to ground with any type of movement too.

Good luck, Eric
Eric L. Bewley                               
Editor, ZUKIWORLD Online                   

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