Reliable dogbone replacement?


Information and questions on GL1100 Goldwings (1980-1983)
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tom84std
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Location: Arlington, Texas
Motorcycle: '84 STD 1200
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Reliable dogbone replacement?

Postby tom84std » Mon Oct 15, 2012 10:20 am



One day near Huntsville Tx. The factory fuse failed on my '79. Dead on the side of the road. I stripped the wires and twisted them together and rode away. I replaced it with an automotive, rubber LARGE horseshoe type 30amp holder and fuse. It lasted six months and then smoked at 2:00AM on the side of the highway. Again, I stripped the wires, twisted them and rode away. I installed an AGC type holder with a 30 amp glass AGC fuse. It lasted six months and melted. Again, I twisted the wires together and rode away. Then I installed a 30amp automatically resetting breaker with #10 threaded lugs. That worked until I sold the bike. Does anyone have a source for a tough reliable fuse holder that will withstand the rigors of being in a motorcycle environment?



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WingAdmin
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Re: Reliable dogbone replacement?

Postby WingAdmin » Mon Oct 15, 2012 10:53 am

I put a 30 amp waterproof fuse holder from Radio Shack, part number 270-1234, in my 1100:



I never had a problem with it, and it was in there for years.

If it truly is rated for 30 amps (and the Radio Shack one is), it should not be heating up. If it is, you likely have a contact problem - between the fuse and the contacts in the fuse holder. Any resistance in there at all will cause heat, and heat will cause more resistance, and eventually it will melt. Corrosion, dirt, any foreign material can cause resistance. Clean both the fuse and the holder with contact cleaner before installing the fuse. Make sure that a good quality terminal ring is crimped AND soldered onto the wire ends. Make sure the wire is of appropriate size (10 gauge).

If the 30 amp blade fuse is not blowing, then you are not overloading it. If it is melting, the problem is in the holder and/or the fuse itself.

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tom84std
Posts: 493
Joined: Fri Jul 13, 2012 7:40 am
Location: Arlington, Texas
Motorcycle: '84 STD 1200
2002 VTX1800
2007 Shadow 750
69 BSA Bitsa
2004 Virago
VW Trike

Re: Reliable dogbone replacement?

Postby tom84std » Mon Oct 15, 2012 11:25 am

WingAdmin, that appears very similar to my first attempt. That's the one which failed me on the side of the road at 2:00AM. I fully understand how current+resistance=heat.(OHM's law) and that's what caused the similar one I had to fail. I'm actually ready to try the one you suggest again on the chance that unknown factors caused that one to fail. You say you've had one in operation for years and I believe that. I've been thinking of retrying that type and smathering on a bit of silicone grease to exclude the dust and moisture and to help with the vibration.

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virgilmobile
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84 GL 1200 I

Re: Reliable dogbone replacement?

Postby virgilmobile » Mon Oct 15, 2012 12:43 pm

I have gone as far as to cut both red wires from the solenoid,solder the BIG fuse holder direct to them and solder a ring connector that is attached direct to the battery.
This eliminated the plug connections.
I solder everything including the stator wires,all the regulator wires and add the relay to the regulator.
I now have a very stable battery voltage( 13.8-14.4 ) from 900 rpm through red line.viewtopic.php?f=5&t=12522




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