melted a fuses pin???

Hi guys. Some of u may have heard that i broke down on the relay.
Here is a pic of my melted fuse.




it has been suggested that the fuse holder may have had a loose connection and that it arced, and melted the fuses leg, before it blew the fuse???

I think this theory is a sound 1. any other ideas??

I have searched and found no obvious hot spots on the wires. I replaced the fuse and she runs. I have bought a new fuse receptacle to replace the old 1.
I just thought I would ask everyone’s opinion, before I go any further.
Should I bother to start cutting into the harness or just ride on.
I’m thinking I should make some changes over the winter. Maybe separate some circuits and add fuses to them, or would it be easier to start over with a 78 or newer harness that already has more fuses??

It seems to me that if the bike's wiring shorted out enough to burn that fuse without simply blowing it there would be some burned wires that would be easy to spot. So I would guess that it was the fuse or fuse holder itself that was defective. After you replace the holder and fuse and run the bike just check to see if any wires are getting hot. Ed

i'll be looking at it closely this week. anyone know of a good suplyer for nice soft plastic wrapped bullet connectors, and fuse block and such??

For all intents and purposes a short will blow a fuse, a bad connection at the leg will cause major heat and burn. So I'd say you are relatively safe in assuming the fuse and fuse clip had a weak connection. Lot of chinese fuse clips out there won't flow 1A. That setup you have there doesn't look factory Don't buy fuses or fuse clips through Radio Shack, Autozone, Walmart or any of the other Chinese parts houses.

good advice. thanks
where can i find a good suplyer for nice soft plastic wrapped bullet connectors, and fuse block and such??

Here is one place to get good quality electrical, www.oregonmotorcycleparts.com/connectors.html
Might as well do the Fuse Box conversion. Then if you decide on a new harness, you can just wire it back to the panel. Maybe make a change if you didn't like something on the 1st (Old Harness) try.

thanks. i dont see any ground side blocks. any ideas where to get 1 ??

www.easternbeaver.com is a good website for electrical items.

Also look in harborfreight.com. Sometimes you find gold for pennies there

Thanks guys. great stuff.
any more ??

mark1122 wrote: thanks. i dont see any ground side blocks. any ideas where to get 1 ??

A ground/ earth junction block, is that what you mean? so you would bring all the connections back to it, like an bus bar in a circuit panel?
There are such Gang connectors available. But the more usual way would be to have those come to a splice, then continue to a main ground on the frame or back to Batt neg. Wire dia must of course be able to handle that. A couple of ground terminals to the frame, with splices to the individual components, is the usual set up.

yes thats the idea. i have 4 or 5 ground wires on my bat for thing i've added. i just thought there may be a bus bar type connector i could clean it all up with. ?