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Ochoa0042
Posted on Wednesday, February 06, 2013 - 02:57 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

my relay box seems to have overheating and melting issues and this is also led to fried relays.
it's getting too much amps but I'm sure the fuses are correct. what gives?
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Tq_freak
Posted on Wednesday, February 06, 2013 - 03:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Check your grounds.

added resistance somewhere makes things heat up
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Rays
Posted on Thursday, February 07, 2013 - 12:16 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It could just be a poor connection in the female connector/s the relays plug into.

A loose connection can arc and create a resistive connection which will then start to generate heat that can add to the resistive connection and generate more heat etc etc. You don't need a lot of resistance to start to generate some serious heat with the normal current draw of some of the relays.

The relay box can be split apart and that allows you to look closely at the sockets. Some might be able to be cleaned and squeezed together to provide a nice tight connection but if they have really overheated then you will need to replace the socket.
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Ochoa0042
Posted on Thursday, February 07, 2013 - 06:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

the 87connection to the KeySwitchRelay is melted
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Rays
Posted on Friday, February 08, 2013 - 07:46 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

This thread has some great pictures of what might be your issue and instructions on pulling the relay block apart.

http://www.badweatherbikers.com/buell/messages/327 77/583876.html?1283308981
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