1st gen main fuse information

[dingy]

The 88 I recently bought had an electrical issue that was related to main 40 amp fuse block that is located right off the positive battery post. The slightest movement of fuse block would cause bike to lose all power. I pulled the fuse block out of system and discovered that at some point someone had the main fuse blow and they decided to put a straight jumper in place of the fuse. Intermittent issue was due to one of the wire clamp screws being loose. I had 2 other spare main fuse blocks and was going to swap one of them out for the defective one. Opened 1st one up and similar alteration had been done it. Other one had a mud dauber wasp nest built in it. None of this is particularly amazing considering these are from 25+ year old bikes.

 

What I did discover though was that inside of the main fuse block there is at least one spare fuse in a slot in the case that I did not know about. I looked in the Service Manual and did not see it noted in there either.

 

I ended up making a new main fuse block out of components I use for battery cable sets I sell to replace the oddball main fuse, much easier to replace an ATC style fuse than the stock one out on the road..

 

Something you might want to check on your bike, that main fuse being bypassed is not a good thing. A failure of the rectifier/regulator is 1st thing that comes to mind. A short circuit in R/R unit is only protected by the main fuse, a bypassed main will lead to extremely high current flowing in some of the wires, the result of which could very well be a fire.

 

I would suggest that if you are working in area of battery that this be checked. 2 out 3 that I had were bypassed like this. And also check and see if there is a spare fuse in there. 2 of the blocks each had 2 spare fuses inside. One of the pictures shows spare fuse setting upright in the spare holder.

 

Gary

Edited April 12, 2015 by dingy
added picture of stock fuse and replacement one.

[Brenner]

Thanks for sharing, it is something far too easy to overlook. As you mentioned one can only guess what a previous owner has done to a bike of this age. Now I have to go check mine.

[Prairiehammer]

I knew about the spare main fuse link in the fuse holder, but it was used already on my '83 so I ordered another fusible link as a spare. Part number: 707-82151-00-00, $2.37 each at Boats.net

For those of you who haven't upgraded to the ATC fuse, perhaps you should check for your spare fusible link, too.

[bongobobny]

I like your upgrade Gary!!

[Flyinfool]

Dingy

In one of those pics it sure looks like one of the jumpered fuse holders the wires were melting. Someone was real close to letting all of the smoke out of their bike. I wonder what the rest of their wire harness looks like.......

 

There are supposed to be 2 spare fuses in that slot. I can understand there being no mention of the spare fuse in the service manual. A tech in the shop should replace with a new fuse and not use up the bikes spare. I have not looked but that spare should be mentioned in the owners manual.

 

I found my spares while I was upgrading to the MAXI fuse. I turned the fuse holder over and they fell out.

 

I did a similar upgrade but I used a MAXI fuse.

Even though they make a 40 amp ATC fuse, the contacts will get warm to hot with continuous power draw of high 30s. While it is probably still safe, It is to close to the edge for my taste. But then I am the master of overkill.

[dna9656]

Technically this is the 85 but the 83 looked just the same.

 

I Had this:

 

http://i280.photobucket.com/albums/kk195/dna9656/th_IMG_0252.jpg

 

 

This is the 83/84.

 

I did this:

 

http://i280.photobucket.com/albums/kk195/dna9656/th_IMG_0254.jpg

 

The circuits are named on the other side of the fuse block. The value of the respective fuses are labeled here, the 15 amp fuse on the left a spare pushed into a spare circuit location. It now holds a 3 amp fuse for the heated seat.

It all fits where the original fuse panel was.

Edited April 16, 2015 by dna9656

[flyday58]

When I upgraded my battery cables Gary included the same fuse as in his photos. I like it, made for a clean installation, looks good. I had two of the old-style fuses, but only one had the spares. I found them the same way Jeff did.