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Main fuse replacement.
As our bikes become older and new owners for older bikes find that there recent purchase isn't completely 100% there are some things that can be done to improve on the original.
One of these is the replacement of the main dog bone style fuse with a 30 AMP weather proof style auto fuse holder and fuse.
If your bike is having power problems this is the first place to start.

On the right side of the battery is the starter solenoid along with the main fuse inside a plastic housing.
If there has been evidence of burning or heating around this area and the plastic melted, there are two ways to solve the problem.
One replace the solenoid and plastic housing with a new one. $$$$$$
Usually the solenoid is OK and only the plastic melted.
Remove the NEG lead from the battery, remove the POS lead from the battery. If the wiring is burnt, cut the wiring back to shiny metal and replace any sections with new wire of the same gauge, identifying the original colors if you cant get the correct colored wire.
Remove all the burnt plastic so that only the solenoid is left along with two spades.
Connect the RED and RED/WHITE wires together and connect them to one end of a 30 AMP auto fuse holder, using solder and heat shrink tubing.
The other end of the 30 AMP fuse a 1/4" eyelet is soldered on and connected to the post where the heavy RED wire is connected to the solenoid or the POS side of the battery (your choice) These two red wires provide power to the IGN switch and memory for the radio and clock so they are live all the time.
On the other two wires GREEN/RED & YELLOW/RED solder a female spade the same size as is on the solenoid.
Connect these to the two spades on the solenoid.
Tape up the wires so that they are neat.

Attached Files
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.jpg   solenoid rewire.jpg (Size: 54.15 KB / Downloads: 379)
The only stupid questions are the one's that are not asked.

#1 04-22-2008, 06:43 PM,
I carried out Rick's modification as detailed in his post as I had a melted plug. My electrical problem is fix with this modification. In addition I replaced my 4 year old battery.
97 GL1500 Lehman Trike
85 GL1200 A
Mount Hope Ont
#2 05-02-2008, 04:13 PM,
I plan on doing this fix shortly but was looking at the main fuse today and noticed the fuse holder has 50 AMP stamped on it. Does that matter in light of the 30 AMP recommendation?
#3 05-09-2008, 06:55 PM,
Ian, if you've bought an automotive in line fuse holder with a fifty amp fuse, you're in good shape. Remove the fifty and install a 30 Amp fuse as recommended by the factory. The fact that your replacement holder will handle fifty amps, reduces the chance of overheating the fuse holder and wiring. (heavier guage)
#4 05-09-2008, 07:06 PM,
Mike, I haven't bought an inline item yet. The 50 AMP to which I referred is stamped on the bike's main fuse unit. I was just asking why a 30 AMP is considered a practical alternative.
#5 05-09-2008, 07:14 PM,
As far as I know, Ian, the '84 Aspencade main fuse was only rated at 30 amps. Is there a 50 amp in the holder now? I'd like to see a pic to get a better idea of you're talking about.
#6 05-09-2008, 08:00 PM,
Sorry guys, these old eyes ain't what they used to be. I re-checked and it is 30 AMP, not 50 AMP. Whew!
#7 05-09-2008, 08:34 PM,
Once again, the information provided by members of this forum has been invaluable. I decided to change the main fuse as outlined by tricky and must say, I'm sure glad I did! The old original item was not fully melted but was certainly well on its way.

The changeover was pretty straightforward - just follow tricky's step by step instructions - and has made me feel better now that I don't have to worry about a meltdown in the middle of nowhere!

Thanks guys!
#8 06-04-2008, 11:48 AM,
Hey Keener- check the connections at the voltage regulator- if it was that bad at the relay/ main fuse then there is a higher chance that the connection under the shelter may be as bad or worse- mine sure was
currenlty own
Car, truck, and bicycle :)
formerly owned
86 SEI,83GL 650i,82GL 500i
450 nighthawk, german spec CB 650, KZ 100, YZ 125, CT90
#9 06-04-2008, 06:10 PM,
Thanks for the tip, Tim. I'll check it in the morning.
#10 06-04-2008, 06:37 PM,
tricky, could you repost the pics in this topic? I am working on an '84 Aspencade and some of the wiring looks a little worse for wear.

1984 Aspencade
#11 01-06-2009, 08:14 PM,
aspengold Wrote:tricky, could you repost the pics in this topic? I am working on an '84 Aspencade and some of the wiring looks a little worse for wear.


Done Smile
The only stupid questions are the one's that are not asked.

#12 01-06-2009, 09:42 PM,
fortunantly we had the 30 amp fuse holders at work. i already changed the one for the 750f and havefuse holders for the other bikes waiting to be installeed
'75cb750 ,'79cb750superK,
'93gl1500se, '79cb 750f,
'85cb450sc, '05sunL70
'06 ST 1300....william
#13 01-07-2009, 05:37 AM,
Thanks Tricky. The pics help a lot ! With the help I have found on this board..I'll get through this wiring mess before spring.

1984 Aspencade
#14 01-07-2009, 09:57 AM,
Thanks all! The info was very helpful. I replaced mine and am good to go. I was having intermittent loss of power. The bike would shut down completely until I wiggled the fuse a little. Then I could restart and be good for a little while. Very frustrating and embarrassing.
Thanks again! ^Smile^
#15 04-22-2011, 05:46 PM,

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