Hot main fuse wire

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timma11
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Hot main fuse wire

#1

Post by timma11 »

Hi, its been a while since I posted. That means all the help given here has worked!! Thanks!

Todays problem is a power issue. The main wire that comes off the magnetic starter switch near the battery and goes to the main fuse gets hot. The wire on the other side of the fuse gets hot too, but not as much. The main wire will heat up and cool down depending on engine rpm.
https://drive.google.com/file/d/0B9Vc48 ... sp=sharing

Also, the charging system seems a bit off. The battery is getting up to 15.4 volts at high rpms and will drop down to about 13.3 volts at idle.
https://drive.google.com/file/d/0B9Vc48 ... sp=sharing
Thoughts?
Tim
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oldwings 78
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Re: Hot main fuse wire

#2

Post by oldwings 78 »

Resistance causes heat. Corroded dirty connections cause resistance. I would clean all the connections at the starter, chassis ground, solenoid, battery and then take out the three wire connector at the stator and solder and shrink wrap the three yellow wires. Replace the dog bone fuse (the main fuse) with a spade type fuse holder and fuse. (solder that in as well) After all that I will wager that your hot wires are a thing of the past. Hope that helps you.
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timma11
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Re: Hot main fuse wire

#3

Post by timma11 »

I have done almost everything you outlined. Click the top link and you can see a picture of the new connections and fuse. the only thing I haven't cleaned is where the orange wire goes to. I will do that next.
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Re: Hot main fuse wire

#4

Post by duke182 »

Sometimes wires corrode inside the insulation.
If your problem persists you might want to consider new wires also.
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rnelson
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Re: Hot main fuse wire

#5

Post by rnelson »

Seems like those wires do get hot. I noticed that the insulation on my red wires in that area were hard and cracked. I need to do a new fuse like you did. My dog bone disintegrated when I opened up the box to look inside.
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Re: Hot main fuse wire

#6

Post by Toehead »

Tim, I would check that your regulator is getting the correct reference voltage. Unplug the regulator, and find which wire gets battery voltage when you turn the key on. Now, plug the regulator back in, and read the voltage on that same wire with the regulator plugged in and the bike running.

It should be the same as the battery voltage. If it is lower (say 14 volts at high RPM when the battery is reading upper 15 volts) you have dirty connections between the regulator and battery causing a voltage drop.

If that is the case, you can upgrade to a combo regulator/rectifier off a new bike and never have to worry about it again.

Also, the 15.4 volts you are measuring is why your batteries only last a year!
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RB
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Re: Hot main fuse wire

#7

Post by RB »

sounds like you regulator is shot..not dumping extra V's..cleaning connections a good idea as well.
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ericheath
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Re: Hot main fuse wire

#8

Post by ericheath »

Too bad you don't have another bike to swap regulators. If one was a known good bike, charging in the normal range, and you swapped yours into it and it was still high, then you could conclude it's your regulator. If not, it's connections or as Duke said, corrosion in the sheaths of the wires.
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Re: Hot main fuse wire

#9

Post by Toehead »

Tim, as discussed, I'd recommend buying an all-in-one unit. This eliminates the external sense wire that causes so many issues. There are a bunch of generic ones on ebay, liker this one:
http://www.ebay.com/itm/Voltage-Rectifi ... 78&vxp=mtr
This should basically be plug and play for you.

The only concern with those is that they are made in china. If you want one that is a little better quality, a used CBR600RR regulator works as well. You will need to cut off the plug of your rectifier and solder it to the wires on your new CBR600RR regulator/rectifier, but the wire colors match.

http://www.ebay.com/itm/03-04-honda-cbr ... 12&vxp=mtr
2012 Golf TDI, fast and frugal oil burner
1980 CX500C, All around road warrior (Sold)
1975 TS125 (Sold), old smoker
1977 naked GL1000, Highway cruiser
'81 GL1100 14,000 (reconditioned and sold)
'81 GL1100 50,000 miles (under construction)
2X 1981 CM400 beginner bike (sold)
1980 CB750C (sold)
1994 Virago 750 (Wifey's bike)
'76 GL1000 Sulphur Yellow (Megasquirted efi build) http://www.ngwclub.com/forum/viewtopic.php?f=47&t=59774
olchris
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Re: Hot main fuse wire

#10

Post by olchris »

Toehead wrote:Tim, as discussed, I'd recommend buying an all-in-one unit. This eliminates the external sense wire that causes so many issues. There are a bunch of generic ones on ebay, liker this one:
http://www.ebay.com/itm/Voltage-Rectifi ... 78&vxp=mtr
This should basically be plug and play for you.

The only concern with those is that they are made in china. If you want one that is a little better quality, a used CBR600RR regulator works as well. You will need to cut off the plug of your rectifier and solder it to the wires on your new CBR600RR regulator/rectifier, but the wire colors match.

http://www.ebay.com/itm/03-04-honda-cbr ... 12&vxp=mtr

Dont be concerned as this was all about 6 months ago.... probably resolved by now and the "feedback" is still to come....
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Re: Hot main fuse wire

#11

Post by Toehead »

He had actually just sent me a text message asking for more info, so I figured I would just post :)
2012 Golf TDI, fast and frugal oil burner
1980 CX500C, All around road warrior (Sold)
1975 TS125 (Sold), old smoker
1977 naked GL1000, Highway cruiser
'81 GL1100 14,000 (reconditioned and sold)
'81 GL1100 50,000 miles (under construction)
2X 1981 CM400 beginner bike (sold)
1980 CB750C (sold)
1994 Virago 750 (Wifey's bike)
'76 GL1000 Sulphur Yellow (Megasquirted efi build) http://www.ngwclub.com/forum/viewtopic.php?f=47&t=59774
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Re: Hot main fuse wire

#12

Post by Track T 2411 »

Good information is good information, no matter how old, lol...
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timma11
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Re: Hot main fuse wire

#13

Post by timma11 »

There was no feedback because as usual life gets in the way. BUT, now life has given me time to start looking at this again. Thanks to Toehead for keeping me in mind.
Tim
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Toehead
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Re: Hot main fuse wire

#14

Post by Toehead »

No problem!

Here is somebody who just upgraded as well:
http://ngwclub.com/forum/viewtopic.php? ... 6&start=15
2012 Golf TDI, fast and frugal oil burner
1980 CX500C, All around road warrior (Sold)
1975 TS125 (Sold), old smoker
1977 naked GL1000, Highway cruiser
'81 GL1100 14,000 (reconditioned and sold)
'81 GL1100 50,000 miles (under construction)
2X 1981 CM400 beginner bike (sold)
1980 CB750C (sold)
1994 Virago 750 (Wifey's bike)
'76 GL1000 Sulphur Yellow (Megasquirted efi build) http://www.ngwclub.com/forum/viewtopic.php?f=47&t=59774
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