Question about 1981 kawasaki Z 550 F

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Main fuse blows when ignition key turned...HELP 1980 Kawasaki kz550 A1

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  • jgyurko Jul 21, 2009

    my first question was in-complete. i apoligize. After boosting from a truck, with all 4 leads, when i turn the key, the main fuse blows.. wires & harnesses are o.k.

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Sounds like a hard short between the main fuse and auxiliary fuses. disconnect the positive battery terminal and measure it with an ohm meter (red probe on positive battery lead, black probe on frame)

Posted on Jul 21, 2009

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Hi, Mooncat1970 before diagnosing your blown fuse issue, check the bottom of your seat, if its metal and comes in close proximity to the positive battery post you need to take the necessary steps to ensure there is no contact (electrical tape, thick rubber insulation, hammer a dent in the seat bottom etc.) You are going to need a wiring diagram from your service manual, a test light, an ohmmeter and plenty of extra fuses.
If you turn on your ignition switch and immediately blow a fuse you have a hard/dead short and is usually easy to find. With a test light connected to the hot side of the blown fuse holder start stabbing the wire/s that leads away from the fuse holder and towards the ignition switch, you test light will illuminate validating the short. When the test light fails to illuminate you have passed the short and need to back up until the test light illuminates, then look in the immediate area for the short.
If you driving down the road for 30 minutes or 15 miles and blow a fuse you have soft/flying short and may take some time and patience to find.
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Some newer bikes aren't supposed to be jump started. Take the battery off the bike, replace the fuse, charge the battery on a proper charger overnight (as opposed to a battery conditioner like optimate). It should now start fine and not blow the fuse.

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To my knowledge, there are no onboard electrical/electronic components capable of shorting and blowing the fuse with out blowing any of the secondary fuse. The main fuse could possibly blow due to a short in the wiring or an exposed/frayed wire touching the body. The three most likely areas would be:
  • wire harness leading to the regulator;
  • wire harness leading to the fusebox; and/or
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Just a start, do postback how things turned up or should you need additional information. Good luck and Thank you for using FixYa.

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