2 Things Kawasaki

martin_csr wrote: 1. 17mm is the wrench size. The bolt is probably an M12 (ie, 12mm threads).

2. You'll need to figure out why the thing melted. something obviously shorted, but what?

I searched the forum and other forums for background on this issue. Nothing shorted. It seems the KZ650 specifically had this nearly universal (among KZ650 owners) issue with the fuse box: the main fuse comes loose from the fuseholder part of the fuse box, , touches the plastic and shorts a fuse.

Do you have a pic of the melted stuff?

My bike has the original fuse box. motorcycle electrics shouldn't be anything to avoid working on. I didn't know much a few years ago.
good tools are handy. for starters get some terminal pin extractors & a ratcheting crimper w proper crimper dies for open barrel terminals for in case you have to replace a brass terminal.

650Dude wrote

....the 20A was blown and the metal part melted against the fusebox.

A little math: 20 Amps x 12 Volts = 240 Watts of power consumption over a long time !!!! = a lot of heat (melting fuse box) = fuse holder loose = short cut to the other fuse holder = fuse blowing !!!

You must have an unnoticed "near by short cut" in your wiring harness or switch assay or other electric component to ground negative.

What have you do or change last before the issue begins?

Michael

Not every fuse reacts like other fuses.

There are different kinds of the same 20 Amp fuses with different reaction times : ultra slow / slow /normal / quick / ultra quick !!!
To protect the circuit or circuit board or components for damages.

I would like to see what the fuses look like in the Z1E item. New or old style fuses? A common mistake is putting a higher amp fuse in place of the blown one. Adding a higher watt headlight or more accessories can cause overheating.
Pic of what you have now?
Steve

Adding a higher watt headlight or more accessories can cause overheating.
Pic of what you have now?

That´s SWest i am talking about!!! Some issues are self made, because not everybody know´s OHM´S (Ω) law.

U(volts) = R(resistances) x I (current)
U = R x I
R = U / I
I = U / R

Had to learn the hard way. 100 watt Marshal halogen pencil beam headlight, overloaded rectifier, regulator, cooked battery and burned wires taught me well.
The fuse blocks are the weakest link so of course the main will get hot. They do with a normal system.
A aftermarket blade style main is the only way to go IMO.
Besides, it left a slot open for my cigarette lighter.:whistle:
Steve

SWest wrote: I would like to see what the fuses look like in the Z1E item. New or old style fuses? A common mistake is putting a higher amp fuse in place of the blown one. Adding a higher watt headlight or more accessories can cause overheating.
Pic of what you have now?
Steve

As I mentioned, this is/was a common problem that plagued KZ650s. Its not a short.

Additionally, on the inner part of the fuse box it tells you what size fuses should be used. I have never in my life, in any vehicle, put in the wrong amp size fuse.

Scirocco wrote: 650Dude wrote

....the 20A was blown and the metal part melted against the fusebox.

A little math: 20 Amps x 12 Volts = 240 Watts of power consumption over a long time !!!! = a lot of heat (melting fuse box) = fuse holder loose = short cut to the other fuse holder = fuse blowing !!!

You must have an unnoticed "near by short cut" in your wiring harness or switch assay or other electric component to ground negative.

What have you do or change last before the issue begins?

Michael

Once again, its NOT a short. This is was a common problem, defect with the KZ650 fuse box.

Mine has the same problem. The original style fuses are hard to get now. That's why I asked about the Z1E aftermarket one.
Steve

SWest wrote: Mine has the same problem. The original style fuses are hard to get now. That's why I asked about the Z1E aftermarket one.
Steve

Bussman makes the original fuses and I find them without a prob at autozone....thankfully!

SWest wrote: Mine has the same problem. The original style fuses are hard to get now. That's why I asked about the Z1E aftermarket one.
Steve

Most motorcycle shops in Canada sell stuff from the Drag Specialities Fat Book and I'm sure its probably the same in the US so a couple of years back I went into my local tiny shop and asked them to get me one of these

And they did and I picked it up a week later.

The following link has a catalog # and description and price
www.dragspecialties.com/products/?productId=472917