I thought this might be of interest to someone else out there. Recently I have had an intermittent fault with my 2010 TE450. It was like the fuel pump sporadically cut out. The bike would cut out then start running again. Sometimes it would cut out altogether, then after cycling the ignition key a few times it would start again. Almost impossible to diagnose really. Well, last weekend the bike stopped altogether after one riding break at the end of the ride. We checked the 3 little blade fuses on the right side of the bike and found that one had blown, and the other 2 had pretty notable corrosion on the blades. Even when we replaced the fuses the fuel pump would not prime when the ignition key was turned on and the kill switch was disengaged. The headlight didn't come on either. When I had the bike home I tested the kill switch and it worked fine. No power was getting through to the fuel pump so it wasn't that the pump had died. A quick visual inspection of the wiring harness didn't show up any bare wires or any signs of shorting out. Anyway, I gave up looking and posted a question about it on my local dirt bike forum. Kindly, one of the members who is a bike mechanic offered to look at the bike for me. I took it to him this morning and within 2 hours he had been through most of the wiring and then discovered the problem. There is a large blade fuse that goes in an electrical junction on the left hand side of the bike under the seat. There was NO fuse there in my bike. We can only assume the fuse had slowly worked itself loose, which would explain the intermittent nature of the bike cut-outs. It must have then come out altogether when we stopped and I just didn't see it had fallen. So, if you're having similar issues it is worth checking that fuse. I have now put duct tape over the fuses in the hopes that it'll hold the fuses in place and also provide some water protection to prevent any further corrosion of the blades. Hope someone finds this useful...
Thanks for posting this, seems we have never thought to check these 2 fuses or at least the one that affected you, I checked mine and the little clear plastic cap is still on top of both fuses: Manual says: Two fuses (20A), on the electric starter contactor (starter relay) These large, yellow fuses are not shown on the wiring diagram, but since they are right on the starter relay, I believe the one you were missing is the Red wire to Yellow with red stripe wire, the Yellow with red stripe supplies the current to the small P fuse, which IS shown on the diagram, supplying current to the Green wire which supplies the P. Relay, which supplies the Green with red stripe wire which supplies fuel pump, coil, and the fuel injector.
