Topic: 73 CB500 Four - Fuse Replacement/Issue

[Chachi]

I found the post below from a previous thread. Does anyone have a pic of this?

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An auto parts store will have a heavy-duty 1-fuse holder that will fit the CB500 nicely. Make sure the wires to the fuse are heavy, at LEAST 16 AWG size, as the 500 has just the one fuse for the whole bike. There are many similar fuseholders out there that will fit those fuses, but have dinky, light wires. Then THEY become a fuse, another bad day's ride...
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My issue... I've owned the bike one day. The signal lights went out, but all other electrical seemed ok. Now I can smell/see the fuse melting the plastic protector cover with just lights on, engine off. The stock fuse holder metal ends look horrible from overheating, like someone held a lighter to them. Fuse is not blown, assuming it's more than the standard 15A.

First thing to try - clean fuse holder metal ends and try 15A? My concern with changing the stock set up is that it doesn't seem to be much wire to work with and I'm hesitant to start snipping what's there. Thanks for any advice.

[dave500]

ive just used insulated female spade connectors,plug your blade fuse into them,too easy.

[Chachi]

That connection looks clean. Thanks.

Any thoughts on where I begin to find the source of the issue? The fuse in there was 30A. All electrical functioned, then turn signals went and while inspecting that with just key on I smelled the 30A melting. So was it melting because the connecters were dirty or are the connecters dirty because it melted? The top connecter is literally charred. I assume if I throw in a 15A it will quickly blow and I'll have to find out why. Any advice appreciated, this is my first bike.

[dave500]

it should be a 15 amp,youll have to disconnect all the gang plugs and clean the contacts,look for any melted wires,,it might be you have to undo some of the tape wrap and look for a melted green wire,if the battery has ever been connected the wrong way arouind it can cause a short in the loom,it can be fiddly but any and all connectors should be undone and cleaned for a start.

[Chachi]

Thanks. Preliminary results are good. I wired in a new blade fuse holder, put in a 15A and left the key on for a bit with head light engaged and fuse didn't blow or melt. I started up for a few mins as well, but did not ride yet. I also took out the flasher relay and when I shook it, parts inside rattled. So I am assuming that is the culprit for my lack of turn signals. I will pick one up later and install tonight to verify.

Note: I used heavy duty butt connectors to wire in blade fuse holder to original wires. Blade fuse connector is 12 gauge wire with a cover for the blade fuse. The original bike wires are smaller, but I had to use 12-10 gauge butt connectors as there were no 14-12, only 16-14. Any issues with using butt connectors or is that acceptable?

[Duanob]

ive just used insulated female spade connectors,plug your blade fuse into them,too easy.

THAT is freakin' genious! as long as it doesn't arc somewhere inside the cover I guess it's fine and dandy.

[Chachi]

Ok. I'm good. New flasher relay fixed the turn signals and wiring in a new blade fuse holder with correct fuse is working fine too. Thanks for replies.