Wanted to ask if anyone has had a problem with corroded fuses on their bikes.

Couple of months ago, I found out I had a leaky rear rocker box seal. When I took the bike in to have that fixed I was told that my security module was faulty. They ordered another one which got stuck in the great flood that closed I5 last week, but that's another story.

Anyway, when they were checking out the system, they found that there is some sort of hole or tube that allows water to drain down onto my fuse panel. As a result, all of my fuses were corroded. They said that they put some type of gel on the new fuses and put in a brand new battery (all under warranty).

I'm wondering if anyone else has had this problem and if so, what, if anything, was done to fix the problem of water running on the fuses.

Thanks.

 

The "gel" they put on the fuses is dielectric grease. It can be purchased at any auto parts store. I use it on every electrical connection/connector on the bike.

I'm not sure though how the warer got into your fuse box.

 

I just checked mine recently, I was chasing down a problem. Mine were not real bad but did show some white residue. I cleaned them up and used some dielectric grease also.

 

They told me that this was some kind of problem with Sportsters. I just know that the one tech said he was going to seal this tube and the next one said that was a bad thing...so...

 

Must be a fault with 2004 and newer.

Dielectirc gel/grease works great on directional bulbs also.

ps. The fuses are the same as you can buy at Sears! Don't buy fuses at the stealership if you can help it!!!

 

Stefan, Thanks for that tip... I will remember that.

 

Yeah I had this problem (hopefully gone) with my 07. If you goto the website XLforums they have a well documented section on this problem.
http://xlforum.net/vbportal/forums/s...ad.php?t=70840

Unfortunately the corroded fuse problem is more common than one would think. My bike has been in the shop atleast 5 times this year for the same problem. The problem with the corroded fuse is that it activates a mechanical component of the bike while it is off. This repeatedly drained my battery.
My shop has done many things to fix this problem. First they put in a new "improved" fuse box thing. Then when this didn't work they just put in a fuxe box thing from an 08 Sportster.
I found that the major symptom for this problem is a unexplainably drained battery. Sometime I could hear a intermittent mechanical noise from near the Air Cleaner. I think it the the fuel pump turning on.