Melting fuse/Hot battery wire

HD2022114

HD2022114

New Member
Hello, Looking for advice, put together a basket case ST90 two years ago, all last summer ran perfectly, this spring pulled it out, fired up on two kicks and ran great but it melted the battery fuse. Replaced the fuse and recently the rectifier and after putting it back together tried to run it again the battery wire gets really hot as does the rectifier. The battery wire gets hot even if the bike is not running and only sitting with the key on.
Thinking it may be a ground issue but I replaced the entire wire harness two years ago.
Lost and looking for advice.
Thanks
 
Did you remove or replace the battery and is it even possible to reverse the wires to the terminals??? Years ago Had a friend accidentally charge his dead battery in reverse causing some very weird issues??? Just thinking
 
Not a bad thought but, My charger will not work if you reverse the battery wires and I did keep the battery on a trickle charger all winter and wondered if that did something to it. I was thinking about replacing.
 
leave the battery unhooked or take out, use a digital multi meter set to ohms, put one lead on the positive of battery lead and probe with the negative side to find your short, a wiring schematic will help you.
 
Following up a year later as I started back on the bike. I did put an ohm meter on all connections and all tested good. The bike had headlight/start stop button was broken. I repaired and re-wired in a new one from a CB350 and the bikes runs perfect now and nothing runs hot. I did research the Y-YW wires which I unhooked as they were connected. These two were connected. These should switch on when the headlight is on to boost charging. When I connect them together and run the bike with the headlight on, my battery wires and the regulator get scorching hot again. Any thoughts or ideas?
 
I have the wiring diagram and have traced every wire. I cannot find any resistance anywhere. I am thinking the alternator could be overcharging, just hoping someone has some experience with that.
 
Yes, my bet is also now on one or more blown diodes in the rectifier. Especially if its the original orange-finned selenium beast. I'd replace it with a much more efficient and stronger silicon rectifier. The GBPC2504-E4/51GI-ND bridge rectifier from DigiKey would be my choice for maybe $8.00 plus shipping, the last rectifier that bike will ever need.

Rick
 
Yes. I have the pinout wiring guidance for that rectifier if you decide to go that way. Its a rock crusher of a rectifier on these six volt bike electrical systems.

Rick
 
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