• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Overheating Main fuse

  • Thread starter Thread starter humhead
  • Start date Start date
H

humhead

Guest
My 78 GS 1000 Is overheating the Main fuse until it melts the solder & plastic in the fuse block. The rest of the wires show no sign of damage or bad connections. Disconnecting the charging system cools it down.
I replaced the R/R, Cleaned all the connections & put it back together. It seems to run cooler now, but I'm still wondering why the fuse didn't blow.
Any ideas?

Terry
 
3 things that come to mind are:

1>Overloaded circuit
2>Loose or faulty connections
3>corroded ground & or connections (loose connections cause arcing resulting in heat, enough to melt the holder to nothing)

Good luck,
Ron
 
Wow! Thanks for the quick reply. I cleaned the connections & replaced some of the short wires near the problem. I'll test it tomorrow & see what happens
 
the tarnesh on the fuse holders builds up enough head to reach the melting point of the solder but the load on the fuse is below the point that the fuse would blow.
I have had this problem and cleaning the contacts good cures it for the short term. replacing the fuse box with a 82 or newer fuse box (or aftermarket) that uses blade fuses cures that problem permanently.
 
Cleaning the tarnish & adding a ground wire seems to have cooled things down. Changing to a blade style fuse box is a great idea. The 82 & up GS fuse blocks are too big :( Looks like I'll have to find an aftermarket one or modify the electric parts mounting plate.

Thanks

Terry
 
I'm having the same issue. The main fuse is melting the plastic around the tabs. It's tarnished, maybe part of the problem.

I was wondering if removing the front turn signals and all of the gauges was possibly overloading the wire system. I'm just testing the harness after chopping the bike. Any thoughts?
 
I ended up replacing my fuse box with a stock replacement and 6 connectors that had turned black from overheating. No problems after that.
 
I tested the fuse block by cleaning the tabs with sand paper and it ran totally cool. To avoid future problems i did replace them with atc fuses. Much much better.
 
Dont even try to repair a fusebox where the connecters have overheated and melted the plastic. The connectors become loose and lose their grip on the fuses and you will always have intermittent electrical problems. Replace complete fuse box with blade type fuses and fix it properly.:)
 
On the early bikes with only one fuse you can easily use two female spade connectors to slide directly on the legs of a blade style fuse.
 
clean up the ground strap at both ends. especially down under the engine. check the ignition switch plug connections and the biggest gauge wires on the positive side.

resistance equals heat bad connections, corroded inside wire sheath,

sometimes extra ground wires up to the coil bases and the triple trees or a fairing mount help an aging system. wont cure it but will help.
 
I did open up the harness and the wiring is suprisingly clean and supple. I did replace most all of the dirty or tarnished bullet connectors with new spade connectors and soldered connections instead of crimped.

Since this is a chopper bobber project, about a third of the wiring has been carefully eliminated. Everything is working now except the right turn signal and that's most likely isolated to the indicator controller box...there's no click from the box when signalling right. Oh well. Until i fix it, that's what arms are for.
 
Usually the flasher relay is not bothered with which side it has to flash. If the left flashers work then the flasher relay is good.

The bulbs, wiring and direction switch for the right side should be checked.
 
paidtothink said:
Since this is a chopper bobber project, about a third of the wiring has been carefully eliminated. Everything is working now except the right turn signal and that's most likely isolated to the indicator controller box...there's no click from the box when signalling right. Oh well. Until i fix it, that's what arms are for.
Click to expand...

You might have some interest in this 550 bobber schematic.

http://www.thegsresources.com/_forum/showpost.php?p=1150484&postcount=1http://www.thegsresources.com/_forum/showthread.php?p=1188110#post1188110
 
Thanks for the help. This forum is awesome. The bobber plan is really close to what I did on my wiring harness. Added some new wires with an HID light kit...lol. totally worth it though since I pretty much only get to ride at night. Had a good first run yesterday.
 
paidtothink said:
Thanks for the help. This forum is awesome. The bobber plan is really close to what I did on my wiring harness. Added some new wires with an HID light kit...lol. totally worth it though since I pretty much only get to ride at night. Had a good first run yesterday.
Click to expand...

Well you should follow the R/R connections and frame grounds pretty close if not the same.
 
You must log in or register to reply here.

Similar threads

Burque73
Questions for the HVAC guys
Replies
11
Views
201
rustybronco
rustybronco
DR Payne
1983 GS550E Reporting In
Replies
9
Views
146
Cipher
C
darrell3001
Hello from San Diego
Replies
17
Views
254
Suzukian
S
G
That old 'Rectifier' question again
Replies
4
Views
527
fastbysuzuki
fastbysuzuki
J
Main air jet and pilot air jet Mikuni BS34SS 49150 on 81 gs1000gx
Replies
3
Views
515
tom203
T
Back
Top