Fuse Block Replacement Ideas...?


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Wingsconsin
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Fuse Block Replacement Ideas...?

Postby Wingsconsin » Tue Oct 16, 2012 1:45 pm



In a previous post I stated that my headlight was cutting out at inopportune moments (like when I was riding).
I also mentioned that I found the fuse for the headlight was corroded and not working well
viewtopic.php?f=4&t=13019

I thought I had it fixed, but recently I was right back to the starting block with a headlight cutting off whenever it had the mind to do so...
Over the weekend I was working on some other wiring (adding a GPS and some LEDs) and found the headlight fuse was not working properly..The headlight was very DIM and when I touched the fuse it got broghter....?!?
So I wiggled it and found it was loose as was the entire fitting for the fuse to sit into... :o

Now I am considering replacing the entire fuse block and fuses with soemthing new....

Other than better connections and a weorking headlight...Will I experience any other consequences of better electrical pathways..? Like a stronger running bike...or better charging..? or...?

I am pretty serious about doing this ..SOON...Any recommendations on fuse blocks that fit nicely in the space provided...?

Any and all comments are appreciated ... :mrgreen:



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Re: Fuse Block Replacement Ideas...?

Postby scotterichmond » Tue Oct 16, 2012 2:22 pm

here is a link to a guy who did just that

viewtopic.php?f=4&t=13326

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Re: Fuse Block Replacement Ideas...?

Postby Wingsconsin » Wed Oct 17, 2012 9:02 am

I took some pictures as I stated the process of changing this out...
I was quite surprised to find the melting and burniong under the headlight fuse...
luckily no major problems ---but it does explain why the previous owner carried dozens of spare fuses in the false tank tray...





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Re: Fuse Block Replacement Ideas...?

Postby WingAdmin » Wed Oct 17, 2012 9:11 am

I can tell you right now what the cause of your overheating is. It's the corrosion on your fuse terminals:

Fuse block
Fuse block


Any resistance in an electrical circuit will generate heat. With that amount of corrosion, you've got significant resistance. When the headlight starts drawing current, the fuse terminals heat up, to the point that the plastic starts to melt.

Use a round wire brush:



Use it to brush the insides of those terminals until there is no sign of corrosion - bright, clean metal only. Then clean everything up with good quality (i.e. CRC) contact cleaner and reinstall the fuses. That should solve your problem.

I had an intermittent failure on my 1100 on my headlight. I pulled the headlight fuse, and the metal caps fell off the glass tube. Over time, the heat from the engine had made the glue holding the caps onto the glass so brittle, that it vibrated free enough to break the filament inside the fuse. Once I found that, I replaced all of the fuses, just to be sure.

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Re: Fuse Block Replacement Ideas...?

Postby WingAdmin » Wed Oct 17, 2012 9:24 am

Here's another option that is probably the one I would go with: replace the entire fuse block with a blade fuse block:

http://www.amazon.com/Blue-Sea-5035-Bla ... B006VELERM



You'd have to fabricate a bracket to get it to mount using the original mount points, you'd have to cut all the wires from the original fuse box, crimp and solder ring terminals to the wires and connect them to the new block, and lastly, you'd have to jumper together some of the source terminals like they are in the existing fuse block - none of which is too hard to do. You'd end up with a modern, reliable blade fuse block, that uses reliable, rugged, easily obtainable automotive blade fuses.

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Re: Fuse Block Replacement Ideas...?

Postby Wingsconsin » Wed Oct 17, 2012 9:38 am

WingAdmin wrote:Here's another option that is probably the one I would go with: replace the entire fuse block with a blade fuse block:

http://www.amazon.com/Blue-Sea-5035-Bla ... B006VELERM



You'd have to fabricate a bracket to get it to mount using the original mount points, you'd have to cut all the wires from the original fuse box, crimp and solder ring terminals to the wires and connect them to the new block, and lastly, you'd have to jumper together some of the source terminals like they are in the existing fuse block - none of which is too hard to do. You'd end up with a modern, reliable blade fuse block, that uses reliable, rugged, easily obtainable automotive blade fuses.


This is the option I am looking to do...
I wanted to buy that exact BLUE SEA box...and it has available jumpers too to make it easy to gang together the first 4 like in the existing fuse block....but it is 8" long (wide) and the space the existing fuse block takes up is more like about 4-1/2"
So I am looking at other options -- but this one is high on my list at this point...


Postings are my opinions based on experience and acquired knowledge.
Your results may vary. Universal disclaimers apply.


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Wingsconsin
Posts: 785
Joined: Tue Jul 10, 2012 1:47 pm
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1983 Suzuki GS850GL - Blue & Black
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Re: Fuse Block Replacement Ideas...?

Postby Wingsconsin » Wed Oct 17, 2012 9:42 am

Here is a view inside the fuse block from the bottom..You can see the ganging bar for the 4 fuses and the other wires...
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WingAdmin
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Re: Fuse Block Replacement Ideas...?

Postby WingAdmin » Wed Oct 17, 2012 11:23 am

Here's a few others that might work, they look to be smaller. I don't like the one with the push-on terminals because of the terminals, but you could solder and heat-shrink directly to them:

http://www.amazon.com/ATC-Position-Blad ... ref=sr_1_1


http://www.amazon.com/Bussmann-BP-15600 ... B001BXKLNQ


http://www.amazon.com/Auxiliary-Automot ... B003JPCZAQ

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Wingsconsin
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Re: Fuse Block Replacement Ideas...?

Postby Wingsconsin » Wed Oct 17, 2012 1:18 pm

I was talking to some people and showed them the picture above of the ganging bar inside the fuse box.
One person told me that ganing bar was likely the ground side of the fuse..I thought it was the positive side of the fuse...?
Now I am really confused..any opinions on that..
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Re: Fuse Block Replacement Ideas...?

Postby scotterichmond » Wed Oct 17, 2012 1:21 pm

Can't have a ground bar there !
It is called a bus bar. supplies the power for ALL the fuses.
It won't have any grounds near this.

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Wingsconsin
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Re: Fuse Block Replacement Ideas...?

Postby Wingsconsin » Wed Oct 17, 2012 1:25 pm

scotterichmond wrote:Can't have a ground bar there !
It is called a bus bar. supplies the power for ALL the fuses.
It won't have any grounds near this.


Thank you..That is what I thought too...
But electrical is not my strength....But I am willing to learn (and that is what I am doing in bunches) ;)


Postings are my opinions based on experience and acquired knowledge.
Your results may vary. Universal disclaimers apply.


Motorcycle Adventure Storys writen by me
http://neverlost-justexploring.blogspot.com/


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