RobertW, I must ask, with all due respect, whether you even read what you have typed before you hit the post button?
Devious1, I must agree with Willy here. You have a significant short somewhere in your wiring harness or a component.
Does the fuse blow only when starting or do you start the bike and then sometime later, AFTER you shut the bike down, you can't start it again?
BTW, holding down the start button forever won't blow that fuse, unless the starter solenoid has a short... but then you most likely wouldn't be able to start the engine at all.
If you can start and run the bike, but when you shut down you can't start it again, you have an intermittent short that is blowing the fuse while you're riding due to vibration... the fuse blows, but the bike will still run from voltage from the charging system (which is after the fuse).
If, however, it blows immediately when you press the start button, the troubleshooting might be a bit easier.
A little more detail regarding the failure - when it occurs, what the exact symptoms are, etc., will help us help you find this and eliminate it for good.
Good Luck and Good Riding!
'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
Last edited by QuadManiac; 01-15-2009 at 01:18 AM.