Persistant Blow of 20A Main Fuse

  • PLUMMEN
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Re: Persistant Blow of 20A Main Fuse

20 Aug 2010 22:26
#392654
Still recovering,some days are better than others.

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  • Old Man Rock
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Re: Persistant Blow of 20A Main Fuse

20 Aug 2010 22:30
#392656
Ah crap... I said the word Electron flow and ole Plumm got a chubby..... (Wood).... :laugh:
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
MIKUNI, RS-34'S...
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

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  • alexnelson
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Re: Persistant Blow of 20A Main Fuse

20 Aug 2010 22:42
#392662
Something caught my eye in your last postings....
Disconnect the headlight harness plug and re-test....
Fuse blowing?

First thing I'm trying when I get home . . .
78 KZ650-D1
K&N pods + 4-1 Pipe
Mikuni VM24 - 7.5/115/#4 Clip
Dyna-S
Dyna 3-Ohm Coils
Vancouver BC

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Re: Persistant Blow of 20A Main Fuse

20 Aug 2010 23:00
#392666
Alex.... D-connect the instrument cluster harness connector as well and re-test... ;)
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
MIKUNI, RS-34'S...
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

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  • Motor Head
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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 07:09
#392704
Those Fluke Fuses aren't exactly cheap either. I've been OK with mine at a steady 10AMP, but somewhere above then Poof it goes.
I remember your thread your post now, did you check that the rubber ring, at the head lamp bucket, where all of the wires come in is in place and hasn't cut into some insulation? There is 2 of these 1 on each side of the bucket.
1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...

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  • alexnelson
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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 21:14 - 21 Aug 2010 21:16
#392865
Went through a good 12 fuses before I ran out working on it today. Unplugged all the lights. Fuse still went. Then things got kinda strange. I had the thing running for a while, the fuse hadn't blown for a good 6 or 7 minutes. I figured "ok. I'm gonna take this thing for a ride". As soon as I sat on the bike the fuse went. This got me thinking. I put a new fuse in and tapped the frame with a piece of wood, fuse went. I was able to reproduce this about five times. Then it stopped. Anyway, back at it tomorrow with more fuses, more meter, less stick.
78 KZ650-D1
K&N pods + 4-1 Pipe
Mikuni VM24 - 7.5/115/#4 Clip
Dyna-S
Dyna 3-Ohm Coils
Vancouver BC
Last edit: 21 Aug 2010 21:16 by alexnelson.

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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 21:21 - 21 Aug 2010 21:26
#392866
"tapped the frame with a piece of wood, fuse went. I was able to reproduce this about five times."

Uhm Alex, wasn't once enough to inform you you have a short occurring under your seat pan due to your fat ass? :blink: :P :laugh: :laugh: :laugh:

Sounds as though your real close to finding your culprit... Once you do, yell out real loud.... Then beat the hell out of that short with your stick....

You'll feel much better... :woohoo:

BTW, not sure about the KZ650 harness runs but for my 900, harness is under the seat pan for the run to the rear tail/brake light assembly....

hmmm....
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
MIKUNI, RS-34'S...
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
Last edit: 21 Aug 2010 21:26 by Old Man Rock.

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  • alexnelson
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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 21:48
#392868
I hope against hope my fat ass is responsible for all of this.

Harness to all my back lights runs right under the seat pan. So, I unplugged it. Fuse still blew.
78 KZ650-D1
K&N pods + 4-1 Pipe
Mikuni VM24 - 7.5/115/#4 Clip
Dyna-S
Dyna 3-Ohm Coils
Vancouver BC

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  • elfmagic17
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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 22:14
#392874
alexnelson wrote:
78 KZ650 D1

I started a thread about this a while back but haven't been able to work on things for a while. I figured I'd start a new thread because so much has changed since the first post.

My main 20A fuse blows as soon as my bike warms up. I fire up the bike and without touching it at all, the fuse will eventually go after about 2 minutes. If I replace the fuse immediately after that and try to start the bike again, the fuse will blow instantly. Sometimes it blows as soon as I turn the ignition key but this is only after the bike has warmed up.

Due to scorch marks and excessive heat (will burn your fingertips) around the connections to the reg/rec, I thought maybe I had a bad reg/rec. A couple people told me to unplug the reg/rec and see if the fuse still goes. So I did that, the fuse still went.

This leads me to believe there is a grounding problem elsewhere, though, I have searched high and low on this thing without any luck. I've opened up the controls and headlamp almost a dozen times, no exaggeration, and can't see anything.

Is there anyway to use a meter to track down something like this? I feel like I'm just shooting in the dark here.
I've never tried it but I'm sure it works, Take a 10 AMP circuit breaker and replace the fuse with it, bike on and circuit breaker kicking in and out use a magnetic compass to follow the wires it will point to the short. Was a trick I was tought in my electronics class in automotive collage at University of Northwestern Ohio.
Kenny Hicks
74 Honda CB550
75 Honda CB360 (runs and rides good but not a show bike)
77 KZ650B1 (Runs Great, but needs painted and a little work.)

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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 22:23 - 21 Aug 2010 22:24
#392879
Thanks a whole bunch, Kenny. :cheer:

Now I've gotta dig around and fine my compass. :laugh:

Good Fortune! :)
1973 Z1
KZ900 LTD
Last edit: 21 Aug 2010 22:24 by Patton.

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  • kawsakiman
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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 22:38
#392888
do you have a new battery?
someday i will be able to afford my kz habit.

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Re: Persistant Blow of 20A Main Fuse

21 Aug 2010 22:46
#392889
alexnelson wrote:
...It all started when I opened my headlamp to tighten the nut holding the left signal light to the headlamp housing. Now you're all thinking, "Well, your problem must be in there!" Maybe it is. But like I say, I've had then thing open so many darn times and can't see anything wrong....

According to wiring diagram for this model, the front blinkers also serve as running lights, always ON, and receiving voltage when ignition switch is ON.

Such continuous voltage is fed through the blue wires into the flashers (probably coming from a dual connector inside the headlight shell).

When tightening the nut, perhaps the blue wire was shorted against the flasher stalk.

If not already done, could disconnect the blue wire feeding left flasher from the connector inside the headlight shell.

And re-test.

Good Fortune! :)
1973 Z1
KZ900 LTD

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