[bdrexel54]

Have an 82 GS750. Purchased the bike recently, ran well until it cut out on me. Noticed that the 15A main fuse had melted but not blown, and the holder itself had melted. Ordered a replacement holder, all seemed well but after a day of riding the replacement holder also melted. Would there be a short somewhere in the system? Bike runs flawlessly besides this electrical gremlin.

 

[Easy Rider]

all seemed well but after a day of riding the replacement holder also melted.

Sounds like something is drawing too much current.
But it is more likely, I think, that there is not a good solid connection of the fuse in the holder.
Or of the holder where it is connected to the wiring.
Exactly how did you connect the new fuse holder ?

 

[bdrexel54]

Sounds like something is drawing too much current.
But it is more likely, I think, that there is not a good solid connection of the fuse in the holder.
Or of the holder where it is connected to the wiring.
Exactly how did you connect the new fuse holder ?

I just used the 7 pin fuse box connector that comes off the factory wiring harness. Plugged the new box in, same issue. I then clipped the factory 7 pin connector to make my own, wired everything up, same issue.

 

[Easy Rider]

I just used the 7 pin fuse box connector that comes off the factory wiring harness. Plugged the new box in, same issue. I then clipped the factory 7 pin connector to make my own, wired everything up, same issue.

I probably would understand that better if I had actually seen the fuse holder and how it is connected.

When you re-did the wiring, did you solder the connections ?
If not, I still think you may have a connection right under the fuse holder that is not solid enough.