Voge blown fuses: DS625X and DS900X circuits and symptoms

Both manuals document the fuse box in detail, and between them they explain most cases of a motorcycle on which something, or everything, has stopped working. The two layouts are quite different, and a fuse chart for one does not apply to the other.

The DS625X: seven independent branches

The DS625X wiring diagram describes seven branches, each fed from the battery positive and each with its own fuse, independent of one another. The fuse box sits under the rider's seat.

Rating	Circuit
30 A	Main supply and charging: EFI, ABS and the remaining electrical load, including instruments and lights
25 A	ABS pump motor
15 A	ABS solenoid valve
15 A	Signal circuit: instruments, lights, horn, indicators, side stand switch, starter relay
10 A	EFI: ECU, oxygen sensor, diagnostic socket, canister valve, injectors, ignition coil
10 A	Radiator fan
10 A	Fuel pump

Spares are carried in the fuse box itself: one 30 A (green), one 15 A (red), one 10 A (blue), two 10 A (red) for the fan and two 10 A (red) for the fuel pump.

The DS900X: one main fuse and nine branches

The DS900X is arranged differently: one main fuse, nine branch fuses and four spares.

Rating	Circuit
40 A	Main fuse: every circuit on the motorcycle except the starter motor
25 A	Ignition switch: EFI, body control module, DC socket, USB, lighting and spotlights
25 A	Control signal: brake light, body control module, instruments, kill switch, horn, USB
25 A	ABS pump motor
15 A	EFI main relay: ECU, radiator fan, ignition coil and injector
15 A	Body control module and lighting
10 A	Charging
10 A	ABS solenoid valve
10 A	Fuel pump
10 A	Radiator fan

The main fuse's exclusion is worth noting: because the starter motor is not on the 40 A main fuse, a motorcycle that cranks but shows a dead instrument points at that main fuse rather than at the battery.

Reading the symptom

The ratings indicate where to look first.

Symptom	DS625X	DS900X
Nothing at all, instrument dead	30 A main supply	40 A main, or the battery
Lights, horn and indicators dead, engine runs	15 A signal circuit	25 A control signal or 15 A lighting
Engine cranks but will not start	10 A EFI, 10 A fuel pump	15 A EFI main relay, 10 A fuel pump
Overheats in traffic, fan silent	10 A fan	10 A fan, then the 15 A EFI relay feed
ABS warning lit, engine otherwise normal	25 A pump, 15 A valve	25 A pump, 10 A valve

Where the fuse is intact and the circuit still dead, the relay is next. The DS900X manual lists six relays: EFI, fuel pump, radiator fan, starter assist, ignition switch and kill switch. The DS625X wiring diagram shows a starting relay, a main relay, a fan relay, a fuel pump relay and a DC socket relay.

The warning both manuals give

Where a fuse blows repeatedly within a short time, there is a fault in the electrical system. Both manuals direct the owner to a Voge dealer rather than to a supply of spares. A fuse that blows twice is indicating where the short is.

What the manuals prohibit

• Only the specified rating is fitted.
• Aluminium foil or wire is never substituted for a fuse. It removes the protection, and both manuals state that it can set the motorcycle on fire.
• A fuse of another rating, or a direct connection bypassing the fuse, is not permitted.
• The fuse box cover is refitted properly. Water entering after rain or washing causes electrical faults of its own.

Before blaming a fuse

A weak battery produces more electrical complaints on these motorcycles than any actual fault, and it can mimic a failed circuit: an instrument that resets, lights that dim, a starter that clicks. The charging figures and the 12.6 V threshold are in battery removal, charging and what it resets.

Related pages

The ratings for the rest of the range are in fuse ratings by model, and the case of a motorcycle that will not start in DS900X will not start.