Inquisitors boost zeal until an inquisition starts, then all hell breaks lose and your population get slightly upset with the idea.
The trigger for an inquisition seems to be more time based than an threshold value of zeal - the longer your inquisitor stays inquisiting (probably not a real word but I like it ~:p) in a particular region the greater the chance he'll start getting that urge to turn a few locals extra crispy - else it would be near impossible to get the occasional 90+% zeal.
If this is how inquisitors do work, then to get a high zeal without burning your population, just move the inquisitor every few years, perhaps moving him back and forth between the same two regions so you end up with two sources for well equipped crusades. I've read that there is a zeal cap based upon the piety of the King &/or governor, but since I prefer 0% zeal regions, that doesn't bother me - my Kings are always poor catholics which is appropriate since I play the English.
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