1992 Kawasaki Bayou 300 4x4 electrical

[S Robinson]

I have a kawasaki bayou as noted above with an electrical issue. I recently had to replace the CDI box. The last one only lasted 2 years or so. Everything worked fine with one exception. When I replaced the CDI I noticed the fuse holder by the battery was melted so I replaced it also. I am only running a 25 amp fuse and the book shows to use a 30 amp. When the ATV is running the wire at the fuse holder heats up too hot to touch in less than a minute but the fuse never blows. What could be making current flow through this and heat the wiring yet not blow the fuse? I am lost and frustrated. I can't ride it for fear of melting all the wiring. HELP.

[bobbyjim]

I don't know exactly which wire your refering to but I do know that a ground wire that isn't grounded ( loose, corroded etc) will heat up. I have seen ground wires on Kawasakis turn red and melt from a loose ground when I worked at a Kaw shop as a mechanic.
If you want to give me more details you could send me a PM. Or list more info here such as color of wire.