Motorcycle Repair: kawasaki 750, motorcycle safety course, amp fuses


Question
Hi Chris...
I am a new bike owner. I bought a used 2001 750 vulcan with 4000 miles on it one week ago. I took a motorcycle safety course where I was instructed to always turn the fuel off when getting off the bike. Inadvertently, I did so and forgot to turn the gas back on when I got going again. As I got to the top of a hill, the fuel ran out and she started shutting down. It backfired one time and then I lost all electricity. No lights, horn, nothing. As I was calling for help, someone helped me find the problem. I had blown the main fuse, and there was a spare, so we replaced it and I was off again. BUT...
when I topped the very same hill again, the same thing happened again. And this time the fuel was on. Now heres the killer. Now its blowing fuses as soon as I turn the key. Not when I hit the starter, AS soon as I turn the ignition to the start position. I am using 30 amp fuses (the green), I dont see any bare wires, ? The bike seems to be in such great shape, well maintained, garaged, etc. But having found a opened pack of fuses in the glove box, this problem was apparently starting to show itself before now.(?)
Is there anything I can do to get her going again, and just for the record, this thing about turning the fuel off. Is it or is it not necessary? I really want to be safe, but I can see where it could be a problem as well.
Helllppp!

Answer
Hi Lee.
 I had a Vulcan 750 and I had a similar problem except it fried most of the main wiring harness.
My solution required a full (11 1/2 hours) day of re-wiring and bypassing the main electrical harness.
 Now, unless you are reasonably good with electrical, then I would take the problem to your local Kawasaki certified mechanic.  Since the bike is used, you may be out of warranty.  Check first.  This could be a problem that Kawasaki is aware of, or it may be part of a poorly advertised recall for that model.  If they tell you that you need a new wiring harness, find out if there has been a recall on that model/year.  Check on the web to see as well.  Kawasaki should cover it if there was.  That is a situation where a dealership is best to handle it.

None of this problem was related to your fuel cutoff switch.  And the reason they tell you to shut off the fuel is because too many instructors ride Harleys, which do not have vacuum actuated fuel valves like the japanese bikes do.

Good luck.
FALCON