I got a new starter recently. The fusible link from the alternator to the battery went. I replaced it w/an in-line 30 amp fuse. The fuse blows instantly and the wires get very hot. The alternator stops charging the battery.

I am going to check the wire coming from the back of the alt. but I'm pretty sure it's ok. What else could be causing this? Should I be checking one or all of the 3 wires that come from the harness on the top of the alternator?

I have 10 gauge wire that i could put a fuse in, but it seems like there would be no point if the problem is another wire somewhere.

 

i lied there's 2 wires coming from the top of the alt. besides the 10g one that goes to the batt.

If one of the fusible links or wires coming from the starter solenoid is bad or grounding out to something would it be cooking the fusible link from the alt to the batt?

When I had the fuse/link in there the link would just melt, but it would charge the batt. Now with the in-line fuse, it blows the fuse instantly. One of the wires coming from the starter looks bad/melted, but it's not touching anything.

I need to get this thing back onthe road. Every time I think I might find a solution, I end up back at square one...

 

Chances are 30A is way too small as these alternators put out ~90A, but please verify what gauge wire you're using with the fuse (or are you just using the stock wiring with the fuse in-line). I understand the 30A fuse blowing immediately, but the wires should not be getting hot unless there is a dead short or if they are too small in circular mils (too high of a gauge number). I think 8-10 gauge and a 90A slow blow fuse should be good, but someone else needs to verify which one of the terminals on the alt charges the battery. I do not know offhand & it makes all the difference here.