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1992 Kawasaki 300 4X4 Wiring Issue

A

Anonymous-0

Well-known Member
Help. I have a 1992 Kawasaki 300 4X4 that has an issue with the wiring. I recently had to replace the CDI box again which was previously replaced only 2 years ago. When I replaced the CDI box I also replaced the inline fuse holder since it was partially melted. I have only been running a 25 amp fuse when the book shows a 30 amp as original. Today I was riding and noticed a hot wiring smell. When I looked under the seat the new fuse holder is again melted. What could be the problem? I have only ridden about an hour since replacing the CDI and fuse holder.
 

Look to see if you have a wire rubbed thu and is grounding. If you have a manual do a check on the stater.
The stater is inside the motor oppsite the clutch. It is made up of "3" coils, low speed , high speed , and lighting coils. Usally when this acts up it's all done "no spark".

Check to make sure the wires going to the external coil are clean and tight on the spades.

The C.D.I sends a signal to the external coil thru the fuse holder.

Does the C.D.I on that model have a metal case or a ground strap that isn't ground correctly ?

I would take apart "ALL" electral connections and clean them ! Put di-electric greese on all the electral connections.

Hope maybe i sparked a thought or maybe a fix .

Jim
 
I have also had units overcharging which takes out main fuse etc. Should be no more than 14.5VDC at battery at around 5000RPM. More voltage will also mess with ignition issues.HTH Bill
 
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