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Discussion Starter #1
Hi, I just got my first Kawasaki Vulcan 750 with 14k miles from 1995.
I have a few problems with it.
The bike would start after 2 days, and run well for 5 minutes, then sputter, and the throttle would not do anything. After this the fuse is blown every single time. Now the fuse blows as soon as the key is turned.
I have replaced the relay, so i do not think that is the problem, unless I have a bought a faulty Starter relay.
Any help would be appreciated.
Thank you
 

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Sounds like you've got a short in the wiring. At first it was probably an intermittent short that would allow the bike to run until the wires vibrated into just the right position and *pop*. Now the wires are in constant contact and blow the fuse immediately.

Probably has nothing to do with the starter relay, since that will only have ignition-switched power when the starter button is pressed.

Does the fuse blow when the key is turned but the engine stop switch is 'off'?
 

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Discussion Starter #3
Sounds like you've got a short in the wiring. At first it was probably an intermittent short that would allow the bike to run until the wires vibrated into just the right position and *pop*. Now the wires are in constant contact and blow the fuse immediately.

Probably has nothing to do with the starter relay, since that will only have ignition-switched power when the starter button is pressed.

Does the fuse blow when the key is turned but the engine stop switch is 'off'?
Yes the engine stop switch will be off and it still blows. I will check all the wires when I am home. When it comes to electrical issues I have very little knowledge with it. Anywhere I should check for grounded out wires first? Thanks for the reply.
 

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Headlight bucket is a good place to check. Along with that check the main harness going back into the frame. Places where it flexes are common spots for wear.
 
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