Fuse box overheating

[Evil Hobbit]

Here's one for you folks. I was on a long ride with the previous owner of my GS1100E (1980), hi taylor. He had warned me that the fuse box heats up and will actually melt the solder in the fuses, well it did it, luckly I carry extra fuses. Any ideas on why, how, and what to do about it.
Chuck

[lartross]

Most likely, some high resistance couplings. [dirty connections] Probally have to do the old, clean, solder and seal a lot of connections.

[earlfor]

Re: Fuse box overheating

Remove the fuse box from the bike. On the back of the fuse box housing, usually you will see a seam line and at one end, there is a small indention.
Place a small flat blade screwdriver and pop the back off. The internal wiring connections will be visable. You will probably find the connections covered in corrosion.

Earl

Here's one for you folks. I was on a long ride with the previous owner of my GS1100E (1980), hi taylor. He had warned me that the fuse box heats up and will actually melt the solder in the fuses, well it did it, luckly I carry extra fuses. Any ideas on why, how, and what to do about it.
Chuck

[Evil Hobbit]

Thanks, I'll do this very soon! In fact I'm going to construct a new fuse box if I can find the matterials.
Chuck

[sv650]

Fuse box materials

Thanks, I'll do this very soon! In fact I'm going to construct a new fuse box if I can find the matterials.
Chuck

I have a the materials needed to assemble a GS1100GK fuse box in my basement. Just needs the screw inserted through the cover & tightened.

David

[Evil Hobbit]

I tore it apart this morning the box is FINE! But, I figured out what is wrong. The regulator is too close to the box. It is an aftermarket that is to big for the space and it is very 5mm from the fuse box. So I moved as for as I could from the box about 10mm and I'm going to go looking for a heat insulator to put between them. Any ideas on what would be good.

[earlfor]

Chuck, if you R/R is getting hot enough to melt the solder on the connections in your fuse box, you have a problem. Have you checked the charging voltage at 5k rpm lately?

Earl

I tore it apart this morning the box is FINE! But, I figured out what is wrong. The regulator is too close to the box. It is an aftermarket that is to big for the space and it is very 5mm from the fuse box. So I moved as for as I could from the box about 10mm and I'm going to go looking for a heat insulator to put between them. Any ideas on what would be good.

[Anonymous]

When I bought that bike the owner told me he had a new stator and R/R installed. I never had a charging problem. I think it is a connection prob somewhere creating too much resistence.

[Evil Hobbit]

Earl It is fine.

[Evil Hobbit]

When I bought that bike the owner told me he had a new stator and R/R installed. I never had a charging problem. I think it is a connection prob somewhere creating too much resistence.

If it was the resistance then the amps would go up and blow the fuse. All they experts here at the school are stumped over this one. I'm going to move the R/R and watch it. It is definetly a new stator and R/R. The R/R doesn't fit in the original footprint for it.

[earlfor]

If your R/R is that hot, it is not going to be fine very long. The R/R on neither of my bikes ever gets too hot to hold my hand on indefinitely.

Earl

Earl It is fine.

[Anonymous]

I would think if it got hot enough to melt the fuse solder it itself would meet it's own doom, like all it's connections unsoldering first.

[Evil Hobbit]

I would think if it got hot enough to melt the fuse solder it itself would meet it's own doom, like all it's connections unsoldering first.

I've come to that conclution myself, new fuse block is in order