melted 30 amp fuse

[rmdrake]

ok heres the deal , started having starting problems , just getting a clicking sound. pulled starter cleaned it reinstalled everything was good for a few days, then started getting clicking noise again, pulled the 30 amp fuse just to take a look and the **** thing is melted, not blown but melted . what tha hell would cause this , i have the EB headlight relays , wally world driving lights, keyless ignition,and airhorn, thats the only eletrical mods ive done , 07 classic 25000 miles, im stumped,

 

[HellFire]

Overheated/melted fuse casing means that you have 29 amps on a 30 amp circuit. lol

It's just maxed out and you should re-arrange some things to spread out the load if you have accessories on it. If it's just the starter all by itself, then the starter motor is beginning to draw excessive amps and is in the early stages of failing ... or your cranking time is too long and it's taking too much time to start the bike.

There is always the slim possibility that the blades are not making full contact and one spot is turning into a toaster oven, but that would probably burn up the fuse box as well.

Those are places to start looking, you will just have to get in there and probe around.

 

[HansO]

if you have all those accessory's running thru that fuse there is your problem as Hellfire said
When I first made up my relay harness for the headlight I also took the power for the Airhorn thru the same fuse and it was to much and the fuse started to melt nuff said I run an extra wire with fuse for airhorn to battery no more melting fuse

 

[Grumpy_Rocket]

Pretty much what hellfire said. Way too much power was pulled through that fuse for that to happen. I will take a look at the wiring diagram when I get home tomorrow, and see what's all on that circuit. If bunch of the aftermarket stuff was wired in on that circuit that's your problem. If not you might have a short or your starter is about shot

 

[rmdrake]

i have my horn , my pc8 fuse panel relay and my baterry tender, direct to battery, keyless ignition, driving lights, and headlight relays going to fuse panel...

 

[Kmutt]

Reroute the driving lights to a seperate supply. They draw alot...especially if they are from wally world...mmost likely from china

mutt

 

[scot in exile]

i have the EB headlight relays ---- so are the EB relays melting the fuses now Check the wallworld lights I looked at them once upon a time and passed on them.

 

[rmdrake]

Reroute the driving lights to a seperate supply. They draw alot...especially if they are from wally world...mmost likely from china

mutt

the running lights or hooked to the pc8 fuse block, the fuse thats mellting is in the main fuse pannel

 

[Lester532]

My course of action would be to replace the fuse and carry a spare.

Fuses are mass produced relatively low tolerance parts. To assume that 100 out of 100 fuses will fail at their rated amperage would be putting too much faith in the machine that manufactured them. The quality control can only do so much.

There may be nothing wrong with your bike. Just a bad fuse.

sh!t happens.

 

[rmdrake]

My course of action would be to replace the fuse and carry a spare.

Fuses are mass produced relatively low tolerance parts. To assume that 100 out of 100 fuses will fail at their rated amperage would be putting too much faith in the machine that manufactured them. The quality control can only do so much.

There may be nothing wrong with your bike. Just a bad fuse.

sh!t happens.

i found the bad fuse while i was at work. so i put in a spare fuse ,when i got to the house checked the fuse and it had started to melt also, now it was out of the same batch as the first so who knows