Electric Problem Page 2
This
single wire and 1/8" connector was not making good contact,
apparently, and generated enough heat to melt the surrounding
plastic connector and create an electrical bridge, thus
shutting down the entire power system
In Figure 4 you
can see the electrical connectors that plug into the starter
relay. Again the single red wire is the wire to be concerned about. You will notice that the electrical connection on one
plug is obviously damaged.
After
discovering this problem it became apparent that to make a
reliable fix that we would have to bypass this entire plug
system and still keep the same 30 amp fuse protection. This
can be accomplished with a suitable fuse holder and wire loop.
First we tapped off the main power feed from the
battery where it connects to the starter relay by soldering a
large enough connector to fit under the bolt holding the hot
lead to the starter relay (Figure 5). The using an insulated
power tap we spliced into the red main circuit wire to create
a new connection for the main electrical feed.
Figure
6 shows the final installation with the green cover back in
place on the starter relay. Once The new fuse and wire is in
place you can use some plastic tie wraps to secure the
assembly to the existing wire harness. By using the same type
of blade 30amp fuse in the new wire connection this allows you
to use the spare 30amp fuse that is located under the green
starter relay cover if you should happen to blow this fuse
while out on the road.
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