Well certainly start with that wire and fuse holder for the 30amp fuse. Sounds as if it is going open intermittently. If its melted, it has gotten hot. if it got hot, its because there was too much current for the wire, maybe because some of the strands are no longer there or there was bad crimping, or something else. But the long and short is that it won't cure itself, only get worse. Replace that wire and fuse holder with something MUCH Larger and solder the connections. It sounds as though your charging system works just fine, but the electricity from the battery is finding an intermittent open. Could be the positive side of the battery, or the ground side.

The ground side is just as important, and you would do well to put in a larger cable than stock. I ran two ground cables from my battery to ensure good connection. If the ground tab on the frame is rusty, you will get this kind of problem. A loose bolt will too. (where is the battery grounded on the Paso?) Start with a volt meter and see if there is any potential between the ground on the battery and any other supposed ground on the bike. if you get any voltage difference, you have found some of your problem. Also make sure you have a good ground to your ignition unit, and any relays that have been put in. If your P.O. put in an ignition relay, it could be failing for a host of reasons.

I would get a cheap voltmeter and connect it to the battery and tape it to your tank. Next time your bike blacks out, you can see if there is good voltage at your battery. If you still have good voltage at your battery when it blacks out, you have a bad connection somewhere.

Check the voltage potential from the battery to the other side of your questionable fuse. If there is any potential across that, that wire needs to be replaced.

Wiring problems are notoriously hard to pin down, but intermittent ones are the worse. I installed a voltmeter on my dash of my 98 ST2 to track its bad behavior. Came in handy. I knew it had blown a regulator before it completely died and had a chance to get somewhere before it stranded me again.

Happy hunting. Phil

Duplicate post, delete
Phil

My inline fuse had melted as well. I couldn't even get the holder apart because it was melted together. But, as soon as I removed the assembly it literally came aprt in my hands. I replaced it with one of the jumbo universal fuse holders and everything is much better. It doesn't get nearly as hot.