20 amp main fuse hot

hi all recently had trouble blowing my 20 amp main fuse i think i found the problem [some badly routed wires going to the starter -frayed-] now bike runs and does everything it should except when i was going to take her for a test ride i said i would check the fuse and boy was it hot just from the bike idleing for a few minutes so i declined the test drive and came in to see if i could pick your brains-i went through the whole harness and all seems to be well except the frayed starter wire which i replaced-any ideas?could it have to do with the headlight?thanks mike

If not already done, would assure integrity of connections at each end of fuse, as these sometimes get corroded and fail to make a good clean connection.

Good Fortune!

A Dremmel tool with a small brush will clean corrosion from the fuse clips. Follow up with some metal polish on a cotton swab.Corrosion causes electrical resistance and heat, sometimes melting wiring and/or fuse holders.

The clips are copper and will corrode if not kept clean.I use a brand of contact cleaner/preservative called "De-oxit" on my clips with no problems. www.deoxit.com is their website.

:S I was riding down a great twisty curvie road out by the Daniel Boon home today when my bike just shut down... Nothing ... It just quit. :ohmy: I pulled the clutch and managed to get into the gravel just before a panel truck came up my ass. After getting off to the side I immediately knew it was my main fuse. I quickly popped the side panel and fuse cover plate and had the fuse changed in no time at all. Why so prepared do you ask? Because this has happened to me at least five times now in the last two years. It has also happened to every one of the KZ guys I ride with that haven't upgraded their fuse boxes on the bike. The cheap fuses get hot and the solder in them melts and you can't see it's a bad fuse. I have a dozen 20 amp fuses with me and a variety of other sizes too. I don't even check them any more, I just replace them and keep going.:woohoo: Don't leave home without them.

get a clamp on amp meter and start checking wires on circuit to see whats drawing juice

:blush: Heck mine is a former Cop bike, and has more loose wires on it than good ones I think ... It would take a complete overhaul of the wireing harness to fix my problems I'm just glad it keeps running as well as it does.

Save your self some future headaches....

Cut the existing fuse holder conductors back a couple inches or more....

Install (Splice, solder, heatshrink terminations) 3 inline fuse holders and install 20amp and 10 amp fuses...