Topic: never trust a fuse / K0 Fuse holder question.

[Don R]

 The title says it all, this is the second fuse in a row that blew like this. The first one was old and worn looking. I'd say more likely failed than blew.
  Both ends are snug too.

[TwoTired]

If the fuse is melting/parting near the end caps, it is more likely that you have a fuse clip heating issue, from either weak pressure contact, oxidized film on the clips, or a nearby junction that has higher resistance than it should (like a failed solder joint).

A simple test to see if you have such an issue, is to flash touch the fuse and clips with your thumb, while the bike is running and everything is switched on.  If there is a problem, holding your thumb on will blister it. (That's why you do repeat flash touches to get a heat memory before holding your thumb on it).  You should be able to hold your thumb on a warm fuse, if all is working well.  If not, you have maintenance to do.

[Don R]

  Thanks for that insight TT.
 I would agree that the fuse clips are not tight enough to make a solid connection, neither are the replacement K0 fuse holders I've bought. I may leave the stock fuse holder hanging for looks and make a blade fuse adapter to replace it electrically.
  My blue-green K0 has a 3 blade fuse holder with extra wires for relays I've yet to install. It was never intended to pass for original though.

[Don R]

Has anyone bought a replacement K0 fuse holder that was tight enough to hold the fuse solidly? If so, where did you find it?

[TwoTired]

Have you tried just bending the clips inward after cleaning?

[69cb750]

Has anyone bought a replacement K0 fuse holder that was tight enough to hold the fuse solidly? If so, where did you find it?

Yamiya, four of them, work good.

[Don R]

Have you tried just bending the clips inward after cleaning?

I did but they seem to have lost their temper, they just don't stay tight and the floppy rubber isn't helping.