Fuse Links

The fuse link is a short length of special, Hypalon (high temperature) insulated wire, integral with the engine compartment wiring harness and should not be confused with standard wire. It is several wire gauges smaller than the circuit that it protects.

 CAUTION: Under no circumstances should a fuse link replacement repair be made using a length of standard wire cut from bulk stock or from another wiring harness.

The higher melting temperature properties and additional thickness of the Hypalon insulation will usually allow the undersized internal fuse wire to melt and disintegrate within the Hypalon casing with little damage to the high temperature insulation other than discoloration or bubbling of the insulation surface. In extreme cases of excessive circuit current, the insulation may separate after the fuse wire has disintegrated. However, the bare wire will seldom be exposed. When it becomes difficult to determine if the fuse link is burned open, perform a continuity test. When heavy current flows, such as when a booster battery is connected incorrectly or when a short to ground occurs in the wiring harness, the fuse link burns out and protects the generator or wiring.