While I try and figure out the AIV system (see other post) my husband removed what was remaining of Secondary Air tubing - someone had removed hard line to the exhaust manifold. Underneath the tubing we discovered the alternator wiring harness burn through. I would love just to replace the harness but can’t find one. We were then going to build it, but I am coming up with a multitude of different information as what is a fusible link, part numbers for connectors etc.
my question, look at the pictures, out of the Alt connector there is the very small y/b wire that goes to its own round connector which plugs in a harness near the left headlight. The other White wires, one is the other wire in the Alt connector and the other grounds on Alt and other end goes into square connector that also plugs in near the headlight. The confusion comes in because the wiring diagram shows 2 whites going into the fusible link. I read fusible links are usually the very small gauge wire and has a specific repair. Since I cannot find which is the specific fusible link to reorder one, I am hoping someone can help me understand how to repair this harness and point to which item is the fusible link. If there is anyone who can point me to the right parts (connector butts) or replacement wires, I sure would be grateful !

Thanks for your assistance!

The one with the fat wires will be the fusible link, the one with the skinny wire will be the diode on the idiot-light circuit. They're not showing the diode being present on the VG30 engine, but the color matches and there's really nothing else it could be, it's either the diode or a straight-through connector.

PS - If that one spot is the only burn-throughs, I'd simply repair it with matching-gauge wire. Cut out the bad sections and splice in new conductors using solder-shrinks. If the shorts caused damage to the female connector pins but they still have spring tension, clean them up with Deoxit and apply dielectric grease when you reassemble so damage to the plating won't get worse.

I can’t thank you enough! This fixing her up has been both an adventure and a nightmare! This forum rocks with all the great advice and people like yourself!

You're most welcome. Stuff that ancient is almost always a problem to reconstruct, so you're almost always better off repairing and saving whatever you can. Since it was a short, make sure you ohm through the fusible link (it should read zero) and the diode (if it is one). If it's a connector it should read 0, if it's a diode it should read about 600 ohms from the wire side to the terminal side, infinity in the other direction. You can fudge replacements for either one if it's bad and the part is unavailable, post back and I'll make suggestions.

Perfect! When it warms up just a tad, we’ll be working on it… supposed to get to 2 (with wind chill) and not warming up much during the day… not very friendly when you’re working with anything electrical…

Yay! Shes alive! Thank you for all your help She even survived the ice storm that rolled through. I don’t know how to post videos, but if I could your would hear her purring like she just rolled off the production line. This forum Rocks!

That's great to hear. You're most welcome, happy motoring!

That's what you get with VStar on board here !!!