Main fuse getting extremely hot please help

I just bought an 82 xj650 Maxim and have no idea what I'm doing on it so guide me like I'm 4. The main fuse is heating up to the point where it melts the fuse box lid and surrounding plastic, the fuse isn't blowing and the bike still turns over and maintains full function with the key on, why is this happening and how do I fix it, would it be beneficial to just buy a new wiring harness and bundle?

 

First verify the size of the current fuses. The main should be a 20 amp and the other 3 10 amp. If they are correct and the fuse is not blowing then likely there is excessive resistance at the clips, a very common circumstance for the original design. There is no need to get a new harness, but upgrading the fuse box is a highly recommended upgrade.

https://www.xjbikes.com/forums/threads/how-to-install-an-aftermarket-fuse-box.6350/

 

if you go for a new fuse box, get one with 4 ins and 4 outs. not the kind with a positive buss, you want 8 connectors not 5
the parts man chacal has them

 

I went through my fuses today and the fuse holder for main has a 30amp fuse in it and the end of that is melted. The original fuse box has been replaced with inline fuse holders with glass fuses in them. As with Dylan the fuse hasn't blown, it's 30 freaking amps, but it's melted.

 

Your RL is supposed to have a 30 amp main, so no worries there.

Poor fuse contact or oxidation at the clip/terminal. The holder is heating up at the fuse.
If there were excessive amperage draw the fuse would have blown.

 

Awesome, thanks k-moe. I bought a new holder today and I’ll install it tomorrow. That should fix the poor fuse contact problem and the intermittent electrical gremlins I’ve been having. Cheers!

 

Make sure that the splice is mechanically sound. A poor splice can lead to the same problem.

 

I wired in a new fuse holder, being extra careful to make sure it's connected properly and heat wrapped it. Then fired her up and went for ten minute blast. Gotta love that beastie!

 

Just ten minutes?

 

So today I put about 110 kilometres on in the rain/shine/rain and loved every moment. Then I had to go to work ☹️. I did my motorcycle skills test on a virago 250 and nearly couldn’t do it I was so cramped on that little bike (I’m 6’4” 220lbs). I did exactly the same thing on my Seca today and it was like walking the dog. Makes a huge difference to have a bike that fits you, that you’re not fighting to move around on.