O/T Kawasaki ATV Electrical Problem

Anonymous-0

Well-known Member
I have a Bayou 300 ATV that has a problem. I keep melting the fuse holder. The book shows a 30 amp fuse and I'm only running a 25 amp. It won't blow the fuse but when I turn the key on the wire to the fuse holder heats up within 30 seconds so much you can't hold it. It has the same problem whether the engine is running or not running. If the key is on the wire heats up. Something is causing continuous current less than 25 amps but hot enough to damage my fuse holder. Anyone experienced this type of problem with a Kawasaki. If it was a bare wire somewhere I think the short would instantly blow the fuse. Any help is appreciated.
 
Loose connection will generate heat. Is fuseholder nice and clean and snug? Could there be a spring missing or a cold solder joint or a bad crimp joint.? Borrow a DC clamp on ammeter and take a reading. What does fuse feed?
 

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