30 amp fuse. - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 17 (permalink) Old 11-3-2019, 7:10 PM Thread Starter
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30 amp fuse.

I managed to pull out the 30 amp fuse at the battery when gutting some stupid lights off a recently purchased ex500. I'm not sure how to wire it back up. The bike will jump start but it will not put more than 8 volts out when I check with a multimeter and any extra electronics load like bright lights or horn kills it. Is it this 30 amp fuse I yanked and how do I wire it back?
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post #2 of 17 (permalink) Old 11-3-2019, 9:11 PM
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The only 30 amp fuse goes to the starter solenoid. The 30 amp fuse above the battery is just a spare. (Not wired to anything)

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #3 of 17 (permalink) Old 11-3-2019, 9:20 PM Thread Starter
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This one was. Maybe just part of the electronics I pulled. I have heard of a 30 amp in this location on this site. Mention of it blowing specifically a 30 amp fuse wired from the positive battery terminal. I actually changed out a blown 25amp to a 30 on mine while in the process of diagnosing a bad battery. That was my determination anyway. New battery fully charged wasn't getting recharged but the bike runs fine after a jump start...I'm at a loss. About to strip it down to the bare min wiring. Would really like to know what that fuse went to. Lol. I figured the stupid underglow lights wiring was doing no good so that was step one for me to pull that crap out. I'm charging my battery now. Start out fresh tomorrow after work.
 
post #4 of 17 (permalink) Old 11-4-2019, 4:06 AM
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In factory trim, that fuse is spare and just sits in rubber holder.

Perhaps someone got clever and plugged wires into it.

To find what it does, just trace wires and see where they go.
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post #5 of 17 (permalink) Old 11-4-2019, 6:47 AM
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Can you post a picture of the fuse and location?
Sounds like someone may have put the 30amp fuse in a 10amp slot. FYI every fuse used in the junction box above the battery is a 10amp fuse. Shouldn't even be a 25amp fuse.

It is a common but poor practice to replace fuses that keep blowing by just using a higher amperage.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #6 of 17 (permalink) Old 11-4-2019, 11:15 AM Thread Starter
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This fuse was not inside the fuse box under the seat it was wired into the connection at the battery terminal the positive one. It was in a single fuse rubber holder with two red wires. It could just be nothing. The positive terminal was loose whenever I started having the problem. After jump-started I left it hooked up to the car I jumped it off of and flipped on the bright lights etc no problems. Whenever I unhooked it from the jump vehicle I checked what volts were coming out of the battery and it wouldn't read above 8. I even revved it up to 4000 and it still wouldn't get above 8 once again this is right after I discovered the loose positive terminal but it is also after I pulled the electronics having to do with the underglow lights. I then switched on the bright lights and it just killed it out. battery is charged right now I will install it and figure some more stuff out after work
post #7 of 17 (permalink) Old 11-4-2019, 11:46 AM
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That's not a stock fuse. The wiring has been altered. May want to check your charging system, and your battery condition.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #8 of 17 (permalink) Old 11-5-2019, 12:03 PM
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What is voltage of battery when everything’s off?
What is voltage at battery when cranking?
What is voltage at battery with bike idling?

Remove every non-stock wiring from bike.
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post #9 of 17 (permalink) Old 11-5-2019, 5:23 PM Thread Starter
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Battery is at 11.98 down from 12.07 24 hours ago not hooked up to anything. Removal of nonstock electronics and wiring in process. Anybody got multimeter specs handy? Stator, starter, solenoid, whatever...I need a new stator cover gasket... perfect time to replace stator! Lol
post #10 of 17 (permalink) Old 11-5-2019, 6:04 PM
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Get charger for battery, those voltages shows it's pretty close to dead.

Measure these others:

- What is voltage at battery when cranking?
- What is voltage at battery with bike idling?
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post #11 of 17 (permalink) Old 11-5-2019, 6:32 PM Thread Starter
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Could my electrical issues have zapped my battery? It was fully charged and resting for 24hrs and is now dead...new battery maintenance free...I think I need a refund. Only charged it twice...
post #12 of 17 (permalink) Old 11-5-2019, 8:16 PM
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Just needs charging. Either by running bike for at least 30-minutes after any kind of cranking or put on charger. Never, ever let battery sit in depleted state after any kind of use without charging. Even to test new turn-signal or taillight bulbs, always put on charger right afterwards.
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post #13 of 17 (permalink) Old 11-7-2019, 1:59 PM Thread Starter
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Will do. Thanks. Haven't done anything for a few days. Im gonna do some oil change etc this weekend. Get into that electrical...
post #14 of 17 (permalink) Old 11-9-2019, 4:27 PM Thread Starter
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Unnecessary nonstock electronics gutted. Battery sufficiently and correctly charged. Bike starts runs with full load brights brake lights etc. After 20 mins running/riding battery read 12.76v ten mins later battery read 12.8v. success. Thank you gentlemen for sharing your wisdom.
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post #15 of 17 (permalink) Old 11-9-2019, 5:40 PM
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post #16 of 17 (permalink) Old 11-9-2019, 10:27 PM
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Awesome job!!!
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post #17 of 17 (permalink) Old 11-10-2019, 2:32 PM Thread Starter
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Thanks! Just checked my battery. Bike has sat for almost 24hrs and still reads 12.8v. Fantastic!
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