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Seat the wiring harness lies on top of the battery. How do you protect the wiring harness from melting

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You can't. A harness will melt if it gets enough heat. All you can do is make sure the airflow around the battery is good. This will also help the battery when it is charging. To protect the harness from meltdown through rubbing you can fit heatshrink tubing or Aramid/kevlar tubing to prevent the rubbing from damaging the insulation.

Posted on May 05, 2013

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Repeated melting of wiring harness of brown/white wire connection. replaced/spliced into new pigtail. Now blowing 15 amp fuse to instrument cluster,tail lights. Any ideas?


If the wire and connection keeps burning /. melting, it would suggest that whatever that wire is supplying power to is overloading the circuit. Trace the wire to see what it is powering and check if the component has shorted / jamming. Normally however, if something is shorting or overloading the circuit, you would expect the fuse protecting that circuit to keep blowing.

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I have an 84 impala and my alternator belt snapped off. Once i replaced the alternator belt, the car started and drove fine except my horn, interior lights, head lights, and tail lights don't work. I...


Circuit Breakers

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One device used to protect electrical components from burning out due to excessive current is a circuit breaker. Circuit breakers open and close the flow path for the electricity rapidly in order to protect the circuit if current is excessive. A circuit breaker is used on components which are more likely to draw excessive current such as the breaker found in the light switch that protects the headlight circuit. A separate 30 amp breaker mounted on the firewall or fuse block protects the power window and seat circuits, as applicable.

Fusible Links

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A fusible link is a protective device used in an electrical circuit and acts very much like a standard fuse. The major difference lies in that fusible links are larger and capable of conducting a higher amperage than most fuses. When the current increases beyond the rated amperage for a given link, the fusible metal of the wire link will melt, thus breaking the electrical circuit and preventing further damage to any other components or wiring. Whenever a fusible link is melted because of a short circuit, correct the cause before installing a new one. Most models have four fusible links.
REPLACING FUSIBLE LINKS

  1. Disconnect the negative battery cable, followed by the positive cable. If the link is connected to the junction block or starter solenoid, disconnect it there as well.
  2. Cut the wiring harness right behind the link connector(s) and remove.
  3. Strip the insulation off the harness wire back 1 / 2 in (12.7mm).
  4. Position the clip around the new link and wiring harness or new connector and crimp it securely. Then, solder the connection, using rosin core solder and sufficient heat to guarantee a good connection. Repeat for the remaining connection.
  5. Tape all exposed wiring with electrical tape or use a heat shrink tube, if available. Where necessary, connect the link to the junction block or started solenoid. Reconnect the positive, followed by the negative battery cables.

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1 Answer

89 quadrunner wiring diagram


Instructions

1

Park the Suzuki motorcycle on flat level ground and allow the engine to cool. Remove the screws or bolts from along the edge of the seat.
2

Pull the seat off the bike's frame and set it aside. Pull the wire harness off the top of the battery, or loosen the cable connector and pull the cables off the battery.

3

Pull the battery from the plastic box. Place the new battery into the plastic box in the same position as the old one.
4

Connect the cables to the new battery, or connect the wire harness to the battery. Replace the seat to the bike's frame opposite the way you removed it.

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1 Answer

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look for burnt wires in the wiring harness any thing close to the motor that could have got hot and melted

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I have a 2003 ford windstar and the wiper wire harness melted any ideas if the computer would cause this


No the computer would not cause this. Wires only melt when the power being forced through them is more than the wire can handle. The excessive power draw is caused by a short or a bad motor with improper fuse protection.

Feb 03, 2011 | Ford Windstar Cars & Trucks

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Took my 1993 VW Fox to a trusted mechanic for a new water pump & thermostat. He called me later to tell me the good/bad news. Good news - water pump & thermostat are in and cooling system ran at...


Hi

for the wires to melt to each other then somewhee in the curcuit they must have been connected, that could have been a spanner sat on top of the battery or something has arked out maybe from the alterator or starter motor, both these parts are around the area of the water pump with the car on ramps

Hope this help. please do bare in mind though that cars of this age do develop random faults so be careful not to blame the mechanic if he is a trusted one, as you don't get many of them.

Regards
Dan

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1 Answer

Crossed battery wires on 2001 ford tarus. When this occured the horn beeped and the trunk released as sparks flew. Immediatly removed the cables and ever since then the car has been burning up...


Hi, yes fuses are there to protect what they are made to protect, but when the main power source is crossed, the dc voltage can and will do a lot of damage. I have seen the electrical wiring ignite and burn the auto to the ground! there is a lot of amps in the battery. This is indeed what is causing the alternator to burn out. You have dead shorts somewhere in the wiring harness, wires that are more then likely burned together and touching, positive to negative at times causing these problems to occur. If you can't locate these wires by testing for any hot wires that are grounded, I would recommend getting this auto in the shop. What will happen if you do not, will cost you your auto, could cost you your auto by causing a fire. This is dangerous when something of this magnitude happens. This is not a minor short in the system, it has caused some major damage. I don't mean to freak you out, I just don't want you to have any further damage. Look it over well, and see what you can do. If you cant find the melted wiring, which it will be melted, take it in. Keep me posted on this.
Sincerely,
Shastalaker7
PS Check around the ignition wiring harness as this is where the majority of wires come into. If you can, pick up a manual on your auto to look over the charging circuit as you are burning out alternators. You may find the problem in that circuit. Alternator, battery cables, starter, voltage regulator is built into the alternator, ignition, and so on. You should be in the right area. Good Luck, and keep me posted.

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You have a short somewhere. If you can trace the wire harness, perhaps somewhere near a heat source causing the insulation of the wires to melt, resulting in the short.

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