Melting?!

[Bayford89IOW]

I have no idea whats causing it but, the starter relay is melting the 30Amp fuse, but when i take it out its all still intact, the fuse didnt blow, it just melts the plastic. However it becomes useless and the bike wont start without a bump start. Wtf is going on? all i can figure out is that the relay is getting too hot?

[extonyg]

check the charging voltage, possibly rectifier over charging causing them to melt.

[cargo]

Could be the relay itself thats faulty

[jake]

I had a faulty coil once that melted my loom together.
which was nice

[Bayford89IOW]

check the charging voltage, possibly rectifier over charging causing them to melt.

I recently had the reg rec replaced, so it cant be that. my guess is the relay like Cargo said, im sure i can find one easy enough. On another note, i found one of the pins on the connector of the reg rec had blackened, so naturally i replaced that and was wondering why it happened, i then had a wander round my loom thinking it must be shorting somewhere and i found a black/yellow wire disconnected under right seat panel. I had a look through my manual and found it was an earth with should've been connected to the battery, does anyone think the earth i found could've been the reason for the reg rec connector blowing?

P.S. i doubt the earth is the reason for the relay melting the fuse, as it did it again yesterday. (4 days after i corrected the earth).

[Jamz]

See? Told you it'd be that!

I bought an entire new solenoid and wiring (to the battery) from a breakers, and that sorted it out for about £30.

You could try checking all the earths and giving them a good clean, but electrics are a bloody nightmare, so I'd recommend replacing the cheapest stuff first and hopefully you'll get the right bit...

[RedexRobB]

The earth connects to the frame, iirc that particular earth connects to the rear shock bracing where the fuel pump is mounted. See pic --->

[Bayford89IOW]

RedexBob Thats an L model frame and setup mate, earths are set in different locations on the H model, for example the earth ur speaking of is being earthed on the engine near the starter motor for me, the earth ive connected to the battery recently is the only earth in the system with a bullet male and female connector (which shows on the wiring diagram). As far as i can figure out its an earth which is connected to all the other earths somewhere down the line. I could be wrong but it seems to have fixed the problem of backfiring.

On the starter relay/solonoid thingy with the 30 amp fuse, i think im just gonna replace the thing and see if it melts anymore fuses.

[RedexRobB]

ahh righto, you hadnt specified that, so there will be a difference. Im sure there are two earths, tho. One on the frame and a seperate for the engine.