Hot fuse problem.

No, only one explanation and that is bad fuse clips. Any short in any circuit will blow a fuse, not make it run hot. Substandard design, and if it was today, they would recall and make them fix it. It really is a major safety issue. When I used to ride in pitch black at 3AM I never thought about deers or drunk drivers or anything else, all I thought of was whether this fuse was going to burn out at 75mph. Over the years since I've owned KZs this problem is always there ready to rear it's ugly head at any time, so always carry a flashlight with you if you ride in dark. Also once the plastic around the clips is melted, you are shit out of luck, as the fuse will never again have tension on the clips, will always run red hot and burn out over and over. At this point you either need a used fuse box that isn't melted, or modify to blade fuses or at the least use zip ties or another method of regaining tension on those crap clips to the fuse.

If you do decide to replace the fuse holder they are still an "Active" Kawasaki part so any dealer can order it, or you can get it from Z1E. See:

www.z1enterprises.com/ItemDetails.aspx?i...KZ900&item=26004-035

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I've seen that many folks replaced their fuse holders with newer types, and I'm sure that is not a bad thing to do. My original holder got a little corrosion after 30 years of use, so I replaced it with an original type in 2007. I figure if I have to replace it every 30 years, and it takes 5 minutes to do, it will give me something to do as I grow old. :laugh: :laugh: :laugh:

built408 wrote: I'm having a strange issue with my electrical system at the main fuse (the one with the white wire) It's getting HOT. With my ignition on and bike running or not it's fine but when I turn my headlight switch on it starts to get hot. I checked the wires coming out by the bulb and I get between 14-15 on the volt meter. With the head light off it's fine . I can't seem to figure it out please Help!!! Also My bike has the h4 conversion.

14-15v sounds high to me.Did you just recently charge your battery?

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Powerstroke_fan wrote:

built408 wrote: I'm having a strange issue with my electrical system at the main fuse (the one with the white wire) It's getting HOT. With my ignition on and bike running or not it's fine but when I turn my headlight switch on it starts to get hot. I checked the wires coming out by the bulb and I get between 14-15 on the volt meter. With the head light off it's fine . I can't seem to figure it out please Help!!! Also My bike has the h4 conversion.

14-15v sounds high to me.Did you just recently charge your battery?

when measured across the bat at 3500 rpm, this is normal.

if i'm not mistaken the white wire on the 78 year goes to the switch. then feeds to the fuse that supplies the headlight.
look at the wiring diagram. maybe u can activate a relay with the lead to the headlight circuit. (The wire going to that fuse from the ignition switch.) The relay would then pull power directly from the bat and send it to the fuse then the headlight.
this would decrease the load on the white wire.

This is just a theory that I was thinking of doing with my 76kz900 over the winter.

WOW thanks guys for the help!! So I tryed sanding the fuse contact that diddent work the fuse is held in so tight that i have to use a screw driver to get it out. I took the switches off the handlebars to see if its grounded but the fuse still gets hot. I checked my battery and the water level was low so I toped it off . I checked my batery voltage at rpm and I was getting almost 17 @ 3000 rpm but It would drop a bit after a few sec. I like the fuse conversion Idea. What do youguys think about the rectifier? Could this be my issue or do you think its the fuse box itself that makes my fuse get so hot? THANKS Paul.

if u r getting a constant 17volts at 3000rpm, that is not good. the regulator should bring it down to about 14.5v. i suspect that the regulator is fried.

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Ya I think your right but wow they're pricey according to the service manual if the power goes up it's the regulator if it goes down its the dyno or the rectifier. I have a strange rectifier tho Im not sure what it is. Check the pic see what you think.