Motorcycle died today... Check your Maxi-Fuse
Tourer
Joined: Feb 2018
Posts: 357
Likes: 205
From: Eastern Washington USA
I’d vote for repair - bypass the weak terminals, solder in some heavy wires with new insulated female terminal ends and Velcro the new fuse in place. Any high amp 12 volt circuit is susceptible to this. My ‘91 EVO fried the big red wire connector under the dash, was at a friends house over night, bike ran fine the day before no power the next morning. Traced it with a circuit test light finally figured it out, he had a wire nut got me home. I soldered that POS connection never another problem.
I have a dim opinion of these “modern” connectors Harley uses now, not enough spring in the metal female side of these things. My ‘04 FLHR voltage regulator connector similar problem, didn’t melt but weak connectors caused a low voltage charge problem, used an oring pick to push the terminal sides back towards center. That 50 amper, once repaired time for functional test, I’d run the bike with all accessories/lights on and feel for heat at the fuse and it’s connections.
I have a dim opinion of these “modern” connectors Harley uses now, not enough spring in the metal female side of these things. My ‘04 FLHR voltage regulator connector similar problem, didn’t melt but weak connectors caused a low voltage charge problem, used an oring pick to push the terminal sides back towards center. That 50 amper, once repaired time for functional test, I’d run the bike with all accessories/lights on and feel for heat at the fuse and it’s connections.
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Tourer
Joined: Sep 2014
Posts: 279
Likes: 315
From: Southern Vancouver Island
Ordered new parts today for Maxi Fuse holder. Price of parts was surprisingly very reasonable and access to remove and replace is also straightforward.
I am back up and running after cleaning terminals and installing new fuse, but once parts arrive, I will be soldering in new terminals and replacing terminal holder etc. with new parts.
Thanks for everyone's input and help with this issue.
I am back up and running after cleaning terminals and installing new fuse, but once parts arrive, I will be soldering in new terminals and replacing terminal holder etc. with new parts.
Thanks for everyone's input and help with this issue.
Seasoned HDF Member
Joined: Mar 2021
Posts: 18,133
Likes: 3,638
From: backwoods
I've read discussion where soldering on vehicles is bad due to vibration. Plus that is a big connection to solder.
Crimp connections are very strong. We crimp wires at nuke plants. Granted we have the right tool that releases when enough force is used.
Crimp connections are very strong. We crimp wires at nuke plants. Granted we have the right tool that releases when enough force is used.
Last edited by Rounders; Aug 21, 2022 at 09:49 AM.
Road Master
Joined: Dec 2019
Posts: 1,176
Likes: 766
From: MS
That's what heat shrink is for.
Seasoned HDF Member
Joined: Mar 2021
Posts: 18,133
Likes: 3,638
From: backwoods
Not sure heat shrink is strong enough to do anything.
Notice everything is crimped on your bike except circuit boards to my knowledge.
Add on top of that, needing to do a good crimp.
Notice everything is crimped on your bike except circuit boards to my knowledge.
Add on top of that, needing to do a good crimp.
Seasoned HDF Member
Joined: May 2008
Posts: 21,096
Likes: 12,640
From: South Carolina
A poor connection will cause excess heat at the contact and melt the metal.
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Seasoned HDF Member
Joined: Mar 2021
Posts: 18,133
Likes: 3,638
From: backwoods
With a crimp the wire is 360 degrees in connector.
Crimps just are not used much. Add on top it may be brittle.
Seasoned HDF Member
Joined: Mar 2021
Posts: 18,133
Likes: 3,638
From: backwoods
Crimping offers stronger, more reliable connections than soldering. Soldering uses heated metal to join the cable to the connector. Over time, this filler metal will degrade, which may cause the connection to fail.
I think you'll be ok. But I don't think it offers the advantage people think. Crping does require special tools.
I think you'll be ok. But I don't think it offers the advantage people think. Crping does require special tools.