Hi all as per title my starter relay fuse holder is melting as seen in the photos below, I need your help with a couple of questions about this and how to cure the problem
1. what is causing this to happen and how do I fix it?
2. where can I get new starter relay fuse holder and the terminal blocks as well?

You've got a short circuit somewhere, which has blown the main fuse but current is still being carried through the ends of the fuse and the case of the relay, which makes heat and melts the plastic... it happened to mine, some time before I bought it. What caused the short, will have to be fixed, but to start with I'd check the wiring and connections to your reg/rec, then the connections to the ignition switch.

You can't get a seperate fuse holder, they're part of the relay, but a new relay is easily available- I got mine from eBay for about £16.

holy fuck...... is the wrong fuse in it ?

Thanks chrissy_j so will I just have to check for a loose connection?
calm down rory I think it's the correct fuse 30amps, and really liked your bike and chris's bike in practical sportsbike this month.

Just had this happen to my cbr600FM (91)....

WTF??
Also blew the starter/ignition fuse & all the bulbs (sidelight/headlight/both rear sidelights...)

Have bought a new starter soleniod/fuseholder off ebay, also a new regulator/rectifier - is obviously overvolting in a typical Honda - stylee... ;o)

cheers buddy.

i have no idea why it's happening but i hope you get it' sorted soon.

If the fuse has not failed then would suspect poor connections within the connector block has generated enough heat to melt the block. Eventually the connection would become so poor that the circuit will be function. This is a high current circuit and the connections need to be tight and clean.

If the fuse has failed then there is a heavy load / short on the circuit that needs fixing.

brido wrote:Thanks chrissy_j so will I just have to check for a loose connection?
calm down rory I think it's the correct fuse 30amps, and really liked your bike and chris's bike in practical sportsbike this month.

Check the wiring around the reg/rec, and pull out the plug connector as well, to check that. You're looking for a loose plug, or signs of burning or melting. Have a look at your battery as well, especially for any signs of bulging or splits caused by excess current and heat.
My guess is that the reg/rec is on its way out, allowing too much current through, it on its way from the alternator to the battery.

The melting occured at the fuse, so this is where the heat was generated.

This is due to a bad connection between the fuse and the fuse-holder. This does happen when water gets in and corrodes the terminals of the fuse-holder.

Bad connection = more resistance = more heat.

I would check over the electrical system to be sure everythings ok but make sure you use a clean fuse and clean up the contacts for the fuse holder and it should be fine.

okay will check all electrical connections from what everyone has said and also as you can see the fuse holder and connector block (that is attached to the loom) is melted, can I get a replacement block which is attached to the loom and if so where
the reg/rec is a yamaha r6 item.