Blowing Main (white) fuse. Help Please? UPDATED

UPDATE::: Took the bike on a 40mi round trip away from the sleepy foggy town of Pensacola today. I cleaned fuse clips as anarki650 had suggested and viola. Im considering the swap to blade fuses though. Gman was so kind as to give up a pic of what the end product will look like, so thank you thank you thank you for every one who responded. Happy riding every body!


SO.....
I have a 1978 Kz 1000 Drag bike. has 1100 carbs on it. very fast smooth running motorcycle up until a few days ago when it died. no lights would come on and the electric start was DEAD.
Checked the fuses and the white main fuse is blowing. Got a new on in it, rode around for about 20 mins and it blows again. put a new fuse in it, blew after 5 or 6 secs, When i put it in gear. Checked the tail light wires, were raw, so i fixed them.
The main fuse *white* is still blowing. Im sure its a simple fix for you all and hope you guys can help me. i thank you very much and love my bike SOOOOOOO much.
Thanks, Ken - pensacola Florida.

Check and make sure that the fuse clips are shiny and clean. I had a kz650 that was doing the exact same thing, pulled my hair out chasing shorted wires only to find that my wiring harness was in great repair. Came down to the resistance that was building up from very very light oxidation on the brass clips for the main fuse. Took a wire wheel on my dremel and shined the clips up nice and bright and never had the problem again.

if it is blowing the main fuse i would be looking for a bare wire making contact with the frame or engine some where for it to keep blowing the main fuse out it would have to be a major short some where do you have any wiring down by the shifter that could be rubbing on the frame or engine also do you have the stock harness or does have a simplified smaller custom built one since your drag racing it.

Here's your wiring diagram.

Follow the lines...

kzrider.com/index.php?option=com_docman&...w&gid=114&Itemid=108

Good Luck!

Thank you Anarki. this will be the first thing i do and ill get back with you guys for sure.

Thanks for the Diagram... wow. ill be scratching my head after i print this sucker out haha

timebomb33 wrote:

if it is blowing the main fuse i would be looking for a bare wire making contact with the frame or engine some where for it to keep blowing the main fuse out it would have to be a major short some where do you have any wiring down by the shifter that could be rubbing on the frame or engine also do you have the stock harness or does have a simplified smaller custom built one since your drag racing it.

Not much else is custom other then the stretch.
ill look for it tomarrow down by the shifter. its raining right now! ugh. stupid rain. thanks, ill look and get back with you guys.

You might want to check under the seat too. I had the same problem and found the main ignition wire (white) and one of my orange signal leads were crushed in the seat latch mechanism and were shorting on each other and the frame.

I had the same problem on my '78. Chased it for a long time. Finally swiched to mini-blade fuses. End of problem. It can indeed be caused by poor contact in the fuse box holders. If you check on a lot of these bike the main fuse will be too hot to touch while the bike is running even if the fuse doesn't blow. With the mini-blades, I feel no heat. Good luck.

Where did you purchase that fuse block? I've been intending on doing to switch over to spade fuses too.

I taced mine to the headlight bucket. There are a bunch of wires that connect in there.

Welcome to KZR

My brother lives in Pensacola too

Gman wrote:

I had the same problem on my '78. Chased it for a long time. Finally swiched to mini-blade fuses. End of problem. It can indeed be caused by poor contact in the fuse box holders. If you check on a lot of these bike the main fuse will be too hot to touch while the bike is running even if the fuse doesn't blow. With the mini-blades, I feel no heat. Good luck.

I took it out to day after roughing up the leads. ran okay for about five blocks before i circled home. The fuse is extremely hot to the touch. I to would like to know where you got your Mini Blade box at. any tips on tackling this sucker? (traced most all the main wires, don't seem to be the problem...)