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General Discussion
Started by Ehnisz at 07-26-2008 10:18 AM. Topic has 10 replies.
  
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 07-26-2008, 10:18 AM
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Ehnisz
Joined on 07-27-2007
Sacramento, CA
Posts 16
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30 Amp Wire - heats up when all 4 10 AM fuses are inplace
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I was checking some of my wiring while the bike waas running, and I came across a set of 4 wires that were VERY warm to the touch. They are under the left cover, immediatley to the rear of the battery. They do not appear to be discolored, but seem way warmer then I can remember any set of wires. OK - almost HOT!
82 GL500i - 14,000 miles
The 4 wires are
2 RED
1 YELLOW
1 GREEN with a RED trace
They come out of the FUSE block and I believe go to the rectifier. At the bottom of the fuse block is a BLACK wire going to the starter.
Any one else have the same condtion? Is it leading up to a future failure - or the nature of the beast?
1982 GL500i - for 1 up
2006 Suzuki Burgman 650 - for 2 up (wife has 2 knee and 1 hip replacement)
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07-26-2008, 11:54 AM
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Shep
 
Joined on 01-30-2007
Hull.East Yorkshire.England
Posts 1,709
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Re: Wires, warm wires to the touch
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To me this would be a sign of a bad ground/earth.On one of my Cxs I had to make my own Heavy ground cable.I bought one from Autozone/Auto discount shop.You can get them in varying lengths to suit the job.
The main black one from the battery on the bike was nearly corroded through where it bolted onto the frame inside underneath the Airbox.as this was hard to get to I chopped it there and fitted the new one from the Negative of the battery to a bolt that holds the Regulator/Rectifier unit on.I think the cable was around 13" I used YMMV.
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07-26-2008, 2:27 PM
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Ehnisz
Joined on 07-27-2007
Sacramento, CA
Posts 16
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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Thanks. My 82 GL may be different - the BLACK wire from the battery goes to a bolt on the starter - took off both ends of this and the RED Battery cable along with the Black cable coming out of the bottom of the 30A fuse block; and brightened them all up. I also took off the rectifier/regulator and cleaned the point of contact for where the two bolts hold it on. I verified I did have a 30 AMP metal strip fuse in the block.
I then took an IR digital Temp (the kind you get at Harbor Freight that point and shoot temps) the Rec/Regulator peaked at 167 degrees while the two RED wires - (one with a white trace) on top of the 30 AM fuse block - hit 150 degrees. The ambient Temp in my garage at the time was 90 degrees. I hit those temps after about 10 minutes at idle (no I did not overheat!).
If this is the norm for regulators.....no wonder we start boiling our water off the battery. The battery sets right above this 'productive' heat source.
1982 GL500i - for 1 up
2006 Suzuki Burgman 650 - for 2 up (wife has 2 knee and 1 hip replacement)
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07-26-2008, 3:21 PM
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DaveF
Joined on 06-11-2008
Lawrenceville, GA
Posts 160
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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I assume you mean these wires that plug into the starter solenoid.
(Photo from main fuse modification writeup.)
The solid red wire is battery power to the rest of the bike after passing through the 30A main fuse link. The red wire with white stripe is from the regulator/rectifier and provides charging current to the battery and also provides power to the rest of the bike. The other two wires connect to the starter solenoid coil and only have current flowing in them when starting.
Since the red and red/white wires both got hot, it sounds like there is a heavy load somewhere in the bike's wiring, not a battery problem.
Are there any aftermarket items added that would consume extra power?
You may want to try removing the fuses located at the handlebar bridge to disconnect these loads and see if the wires still get hot.
BTW, it's normal for the regulator/rectifier to run hot as it's a shunt regulator by design. All excess power from the stator not used by the rest of the bike is dissipated as heat in the regulator/rectifier.
My Home Page
1981 GL500I
1982 GL500I
1983 GL650I
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07-26-2008, 6:11 PM
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Shep
Joined on 01-30-2007
Hull.East Yorkshire.England
Posts 1,709
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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 Ehnisz wrote: | Thanks. My 82 GL may be different - the BLACK wire from the battery goes to a bolt on the starter -
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Are you sure?There should be one Heavy duty Black cable going to and attached to the insulated starter nut on the outside of the starter motor that leads back to the Solenoid?
If there is another one then that should be going to ground/frame?
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07-26-2008, 6:50 PM
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DaveF
Joined on 06-11-2008
Lawrenceville, GA
Posts 160
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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Just to add to the confusion- on the GL's, the black negative battery cable connects directly to one of the rear starter mounting bolts (ground or earth  here).
The positive battery cable connects to one of the solenoid copper terminal bolts. Another heavy black wire from the other solenoid copper terminal bolt connects to the starter terminal bolt.
My Home Page
1981 GL500I
1982 GL500I
1983 GL650I
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07-28-2008, 4:06 AM
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Shep
Joined on 01-30-2007
Hull.East Yorkshire.England
Posts 1,709
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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| DaveF wrote: | Just to add to the confusion- on the GL's, the black negative battery cable connects directly to one of the rear starter mounting bolts (ground or earth here).
The positive battery cable connects to one of the solenoid copper terminal bolts. Another heavy black wire from the other solenoid copper terminal bolt connects to the starter terminal bolt.
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Ah.Thats another across the pond/model difference :)
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08-01-2008, 6:09 PM
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Ehnisz
Joined on 07-27-2007
Sacramento, CA
Posts 16
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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Yes, the picture is of the 2 wires I recorded the temps from. I have only the standard faring, AM/FM Clarion II with the CB. No other power unit I am aware of. The spare power supply under the seat is not being used. I have removed the Tape Player and 2 Front Speakers.
I rode home today in 95 degree temps, with the radio off. I do have the front 4 LED displays with Temp, Voltage, time and CB channel, 2 turn/marker lights and the Headlamp. After 30 minute ride, yes, the wires were still in the 140 plus degree range.
I guess at this point, will do as suggest and start pulling fuses out one at a time, and see where my draw is coming from?
Thanks for all your help - if and when I find the answer, I will pull up the post and answer.
1982 GL500i - for 1 up
2006 Suzuki Burgman 650 - for 2 up (wife has 2 knee and 1 hip replacement)
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08-01-2008, 7:50 PM
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mcreviver
Joined on 05-06-2007
Williamsport, PA
Posts 567
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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You can check the fuses but I would also invest in a can of tuner cleaner/contact cleaner and spray all the pins inside those plastic connector plugs. You may have high resistance in one of those and the heat generated is being sucked up the wires. Also check for any melted potting compound coming out of any of the ignition boxes. Smell the parts for a burning indication.
Ron in PA
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08-07-2008, 8:32 PM
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Ehnisz
Joined on 07-27-2007
Sacramento, CA
Posts 16
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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OK I am back after having pulled the plastic cover off the fuse block between tank and the key - 4 10 Amp fuses...as specified on the decal inside the cover.
I can take out all the fuses and no heat on the wires coming out of the 30 Amp fuse. However as I add fuses - the temp goes up.
I did each one individualy - no difference by touch. As I added - and it did not matter which I added or kept open, the temp kept going up. I tried all the different combinations with 2 open and 2 closed - no difference in the 'noticeable' temp.
Once I put in:
2 fuses - noticeable
3 fuses - warm
4 fuses - back to hot coming out of the 30 Amp block..
SO....should I take and replace the wire from the 30 Amp to the 4 10 Amp fuse block? That almost sounds too simple. If so, same gauge wire or 1 to 2 sizes larger? It is 4 - 10 AMP fuses out of a 30 AMP block.
1982 GL500i - for 1 up
2006 Suzuki Burgman 650 - for 2 up (wife has 2 knee and 1 hip replacement)
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08-11-2008, 8:19 PM
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Ehnisz
Joined on 07-27-2007
Sacramento, CA
Posts 16
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Re: 2 Red Wires, hot to the touch - out of 30A fuse block
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OK - You guys are good. I pulled the spades at the 30 AMP location - small amount of discoloration, I brightened them up and the temp has dropped way down - about 110. I also took out the 30 AMP fuse strip and brightened that up.
Now, I checked the top rack of the 10 AMP fuses and those are running hot - about 125.
Do I have to open up the black box infront of the front of the steering stem to get to the disconnect for the fuse block on the handlebar? I see there are two very small screws in the 4 fuse block, but taking those out does not seem to make a difference. According to the parts break down, the fuse block is connected by about a 12" run. I want to break the connector that goes from the loom to the fuse block and shine that red wire connection up.
I have yet to work on the ignition coils as previous suggested - just one step at a time here.
Thanks again for all the suggestions.
1982 GL500i - for 1 up
2006 Suzuki Burgman 650 - for 2 up (wife has 2 knee and 1 hip replacement)
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