reframe it!

[brcree]

Greetings...been awhile since my last posting. I am in the middle of the Great Frame swap over!!!!!! Question: I have found what looks like a fusible link in the wiring loome. It is a white wire on both ends with bullet connectors at each end. The wire between bullet conn. is a bare wire and, it is burnt into. What is this wire for and what do to fix?

[crazy steve]

What year/model bike are you working on? Does the harness match? There are wiring differences between years...

If the harness is unmodified, that's likely the wire from the alternator stator to the headlight relay and the missing bit is supposed to be a diode.

[brcree]

burnt wire.......

I have a 81 XS 1100 S, H. The wire loome is the orig. The patch of wire I am speeking of had a clear tube it ran through....looks factory...this was all wrapped up in black elect. tape..I'm not sure i.e. my question?

[crazy steve]

That was the diode for the headlight relay. They do burn up when they fail sometimes...

A replacement is as close as your local electronics store. The new one should be rated for 50 volts and at least a couple of amps. Install in the right 'direction' for proper operation of the relay.

[brcree]

burnt wire

Thanks Steve......what a great bunch of guys in here!

[CaptonZap]

Steve nailed it. To add just a bit, if you aren't familiar with diodes, they have a printed band around one end. Make sure you put the new one in with the band on the same end as the one you take out. CZ

[ViperRon]

Part number

The Radio Shack part number I used was 276-1114 and the white band (cathode side) goes toward the relay.

[brcree]

frame

Thanks guys....a real big help there! By the way.....there wasn't a diode to be found when I removed the clear tubing. Glad I saw this before I put the loom back on the bike.

[brcree]

diode

Correction....there was a diode, just melted to the clear tubing.

[CaptonZap]

Correction....there was a diode, just melted to the clear tubing.

You might want to put the new one in, and before you button everything back up, crank it up and see if everything is OK.
Normally, diodes are as dependable as income tax collection, and if your diode self destructed, there may be other problems in the loom, which should be rectified (that's a pun, son) before you get everything taped up again.
Using your ohm meter, check for short to ground in either end white wire, after unplugging the headlight relay and the big plug on the voltage regulator.
If all is well, plug the headlight relay back in, and ohm it out. It should NOT be a dead short, but will read the relay coil resistance if it is good.
Plug the regulator back in, and run the engine, while checking for a temperature rise in the diode. If it gets hot, you have other problems.
Take two aspirin, and come back here in the morning.

CZ

[brcree]

diode

Thanks there Cap....got the pun...man! This is all great stuff! Hope to have the beast on the road in a couple weeks!