Melting fuse box on ER-5

[Velocifero]

Last weekend I noticed my headlights were not working, so the first thing I do is check the fuse box and to my horror, I found the fuse for my headlights has melted into the fuse box. I managed to clean up the fuse box the best I can and put another fuse in. Yesterday I lost my headlights again, so it was off with the seat again, but this time the fuse looked intact but the plastic around it was melted. A new fuse fixed it for a while. Does anyone have any idea what could be causing this? and is it possible to change the fusebox?

Recently fitted new battery and regulator.

[finpos]

Make sure the fuse is the correct rating - too low and it might not blow, but it may heat up. Also check the contacts are clean, but I guess you've done that.

finpos.

[WavyGravy]

Hi There, what bike/year is it?

What caused the reg/rec to fail before?

Is the new one getting too hot to touch after a short ride?

Whats the acid level in the battery like?

If the headlamp is the only thing on that circuit then youve got a short in the wiring or are running too high a wattage bulb. if its not the only thing on the circuit then you could try this general test on the electrics

To get enough heat to melt things either means a short or something is drawing too much current, if the cause isnt obvious then with the bike at rest unplug as many connectors as you can reach and switch ignition on and see if the fusebox heats up, (put your hand on other components as well such as the ignition coils, these heat up quickly if theyre shorted) switch off and connect something else and test again, until you isolate the circuit thats causing the problem. If nothing is making the fusebox hot with these tests then the fault lies in the charging circuit.

These tests are just general ones, it might be an idea to disconnect the cdi (if fitted) while doing them If you can tell us the year and model then there might be someone who has experienced the same, and some bikes are easy to diagnose, like old hondas have great electrical components but dreadful wiring/connectors.
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1975 CB125s, 1991 GN250, 1990 Ducati Paso 906
"Don't wake him up - He's got insomnia - He's trying to sleep it off"

[Velocifero]

Its a 2003 C1 model. The regulators, apparantly, don't last very long on these bikes, usually long enough to last the warranty period. I changed it because the battery was not holding its charge any more. the battery is new too.

[WavyGravy]

I suppose its possible youve been sold a faulty reg/rec. so if you have a voltmeter put it across the battery while the engine is running, about 3500 rpm as a general guide anything over 16 volts would be unusual.

providing thats ok then removing the fuse that keeps blowing and seeing what doesnt work will narrow down your search for where the problem is.

if anyone else knows about your particular model im sure they'll post some more help
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1975 CB125s, 1991 GN250, 1990 Ducati Paso 906
"Don't wake him up - He's got insomnia - He's trying to sleep it off"

[Velocifero]

I think I have worked out what the problem was. The fuse for the headlights might have been a loose fit in the fuse box causing it to heat up and melt. This would explain why the replacement fuse melted the plastic but not the element. I have got a shagged fuse box now which looks like it is integral to the wiring harness.

How hard is it to change the wiring harness on a bike? Has anyone done this?

[edd]

its not so much hard as a complete pain in the arse, just trace the wires back out of the fuse box and put an inline fuse in there in place of the fuse box for that fuse.
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Bluespark Automotive - Diesel Tuning for Performance and Economy

[Phil_G]