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Post by jtbtexas on Nov 7, 2012 2:48:00 GMT -5
Hey guys I got my 1980 xs650 not too long ago it was my grandads and it has around 5000 miles on and the fuse for the headlight will blow immediatly if i start to drive off on it and now i think it is doing it to my blinker fuse too. The starter wont disengage and the mechanic told me the compression spring was worn out but i find that hard to believe with only 5000 miles on it. I was wondering if the safety relay had anything to do with it and the fuse and the clips that hold it in for the headlight get really hot when i start the bike. Any help would be appreciated this is my first bike so i want to get back riding!!! Also the fuse problem did not start occuring until after a month or two of riding it.
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Post by grizld1 on Nov 7, 2012 9:14:39 GMT -5
When an electrical component gets hot, it's due to resistance, and the OEM glass fuses and clips are a typical source of trouble. Installing inline flat fuses is highly recommended, and you'd be well advised to go through the harness to clean up connectors and plugs and apply dielectric grease to them. The safety relay isn't the source of your trouble with the hanging starter gears. The wishbone spring on the right side starter gear cluster needs to apply a specific amount of drag, which you can measure with a fisherman's scale. Without adequate tension, gears won't engage disengage as they should, and the starter will grind. Go to www.biker.net for a free download of the factory service manual. The specs and procedures you need are there. |
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Post by jtbtexas on Nov 7, 2012 23:33:09 GMT -5
Where can i get the blade fuse holder that will fit under my seat and is it as simple as saudering the old wires to the new fuse holder and i do not think i am experienced enough mechanically to handle the spring or am i making it harder than it has to be if so can you give me a step by step process of how to fix it. thanks a bunch man
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Post by grizld1 on Nov 8, 2012 13:57:40 GMT -5
The simplest solution is to remove the old fuse block, buy inline fuses with the right gauge wire (16 for the main fuse, 18 for the rest), and solder splice the new fuse holders onto the wires. You can get what you need (marine fuses) at NAPA. Use shrink tube to cover the solder joints.
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Post by XS Rod on Nov 9, 2012 12:42:17 GMT -5
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Post by grizld1 on Nov 9, 2012 17:50:51 GMT -5
Yep, I've looked at that unit, Rod. It's pretty, but I don't know how well stripped wires with no strain relief are going to handle vibration in those terminals; looks like an automotive item to me. Keep us posted on how it holds up.
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Post by XS Rod on Nov 14, 2012 15:42:52 GMT -5
Agreed Griz... it is pretty... and to be honest there are other aspects of it that concern me... it's low profile wasn't one of those. There are four little posts that act like legs for it to be mounted with that are drilled and tapped for mounting screws. I think one of them may need attention already... gotta say the safest place for it would be installed on the bike.
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Post by headcase on Nov 23, 2012 12:17:34 GMT -5
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Post by grizld1 on Nov 25, 2012 21:03:36 GMT -5
That's a nice unit, headcase. I use something similar from NAPA, but my fuse block hooks up with spade connectors, and I had to cut the housing between two terminals and solder a short piece of 12 ga. wire across across to get two unswitched outputs for relays (one relay for horns, one for ignition). With crimp terminals and clip-in bus capability, what you have sounds like a better choice.
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Post by XS Rod on Nov 26, 2012 10:56:28 GMT -5
I like it too Dan... prolly gonna use the one you have there... I have the perfect spot for it. Yo... Griz, I'll save the pretty one for an install with less vibration  |
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Post by headcase on Nov 26, 2012 23:28:21 GMT -5
It helps that we have racks of the stuff at the shop, I just went shopping one day  There are specific terminals to use it correctly, and they require a specific crimper, but it's easy to make do with basic tools if you need to. Also, for bigger jobs, they clip together side to side to make as big a fuse block as you need (in increments of 4 of course.) If anyone wants to try one or two, I can probably get them at cost as long as I don't make a side business of it. Then again...hmmmmmmm..... |
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