The main fuse on a motorcycle protects the electric system when the starting a motorcycle. A bad main fuse won’t let you fire up your Yamaha Virago XV.
The main fuse is a safety device that prevents the other electronic components from being damaged by a surge of electricity shooting through the system. Your motorcycle or car will not start if the main fuse is blown. Solving this headache quickly can save you time and stress when a blown fuse surprises you.
Main Fuse Location
On the 1997 Yamaha Virago XV250, the main fuse is underneath the seat. The main fuse in the 1997 XV250 is a canister fuse so you’ll be looking for a plastic inline container.
The main fuse in the 1987 Yamaha Virago XV535 is also in the fuse box underneath the seat. In the Virago XV535, the main fuse is a blade type.
The main fuse location of the Yamaha Virago is different depending on the different engine size. Thankfully, between the different years, the main fuse location has stayed the same.
Main Fuse Type
When it comes to the type of fuse, you will likely be dealing with two. Some models have a canister while ideally you would to have the blade variety.
The canister fuses can be tougher to find and aren’t as popular. They may be tough to find in remote areas.
We recommend converting your canister fuse to a blade style as soon as possible, to avoid the headache in the future. Thankfully, that is easy to do with an inline fuse holder.
Main Fuse Size
The most common main fuse sizes for motorcycles are 20A and 30A. You can easily buy them from Amazon or your neighborhood automotive store.
With the canister fuses, you may have issues finding them locally. They are available online, so it would be smart to buy a couple back ups.
For under $15 you can buy a box of blade fuses of a wide range of sizes. Make sure you get a set with the sizes 10amp – 30 amp.
These fuses are motorcycle specific, so you will be able to use them in your car when necessary.
How to replace a fuse in a motorcycle
Replacing a fuse in a motorcycle is easy.
The hardest part of replacing a fuse is simply locating your motorcycle’s or car’s fuse box.
After you locate the fuse box and gain access to the fuses, we will need to determine which fuse plays which role in the electrical system. There will be a main fuse and a signaling system fuse.
Note the size of the fuse, be on the lookout for a “20A” or “10A” printer somewhere on the fuse.
With an inline fuse, pull the fuse out by the colored blade portion. Pulling a canister fuse from the center is the best way to remove it.
Looking at the center “vial” or middle of the blade, we can see the fuse. If it’s intact, so a continuous piece of metal, running from one end to another, you are good.
A damaged or blown fuse will have a broken metal connection. Damaging a fuse may cause it to become a dark color. You will need to replace these fuses, otherwise your motorcycle won’t run or a damaged fuse may cause you issues during a future ride.
Replacing the bad fuse with a matching sized fuse (20A with a 20A or 10A with 10A), will fix this electrical issue.
How to replace a canister fuse with a blade style fuse
I made this “upgrade” on my motorcycle. I DON’T recommend it. It was more annoying than anything so I don’t expect to get a lot out of this.
I’m not familiar with electrical systems so it was a struggle for me.
Just my quick thoughts, I would skip this “upgrade”.
I recently made this change on my 1997 Yamaha Virago XV250. I’d never owned a motorcycle with a canister fuse before and didn’t want to have to purchase additional fuses if I ever blew a fuse while cruising around.
Disconnect the Battery
Whenever doing work on the electrical system, make sure to disconnect the battery terminals. Disconnect the negative terminal first and make sure it doesn’t reconnect when you release it.
I like to put the terminal ends into latex gloves so they don’t touch any metal.
Pull out the Old Canister Fuse Assembly
This is easy to do. Work your hand away from the canister fuse assembly. A couple inches away, you will find the bullet connectors.
Disconnect the bullet connectors on both sides of the canister fuse.
Add bullet connectors to blade fuse
After you cut the wiring of the blade fuse kit, you will need to add the bullet connector. Here is the quick guide to doing that:
- Strip about half and inch of the plastic covering off one of the ends
- Grab a bullet connector
- Put a shrink wrap piece of tubing on wire
- Pinch the bullet connector closed with the wiring inside the connector (Make sure the shrink wrap tube is on the correct side of the corrector)
- Warm the shrink wrap around the bullet connector clamp portion
- Repeat for the other side
Replace the Canister Fuse Assembly
Simply plug in the bullet connectors into the connectors, replacing the canister fuse.
Once the new blade use assembly is installed, make sure to install a new blade fuse. The blade fuse kit I bought came with a set.
Time to reconnect the battery connections.
Reconnect Battery
Reconnect the battery terminals, start with the positive terminal. Then connect the negative terminal.
When reconnecting the negative terminal, be careful not to touch your wrench to the motorcycle frame while in contact with the battery terminal.
Test Your Work
Look over your wires. Is there a gap anywhere? Make sure the battery terminals are snug.
Insert the key, and turn it to start. Does everything light up like normal? If nothing happens, fully insert the bullet connectors into the connectors off the blade fuse assembly.
Conclusion
Understanding how the main fuse works and its role in the electrical system is very important. By understanding even the basics, you will be able to troubleshoot any issues.
Step number 1 is knowing where your main fuse is located.
I wouldn’t “upgrade” a canister fuse to blade fuse. Since doing the work myself, unless you have the right equipment (that may have been my downfall) and experience, it may not be worth it.
Main fuses don’t fail under normal circumstances.
Your Virago XV250 or any other motorcycle you may be riding will be in better hands with you knowing how to look over the basics of its electrical system.
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