Fuel System Wires Heating Up - RSI Stage 4
 

The car is an 05 402 with HP Performance TT Kit. I got the RSI Stage 4 fuel system with 3 DW pumps.

There are 3 relays. One for each pump. Two of them go to a red wire and the other one goes to a yellow wire. I had to change the fuse on the red wire multiple times. Also I'm facing an overheating issue to the level that the last fuse I put it was melted along with the fuse housing and it was stuck. The yellow wire has been heating as well but I never had to change its fuse.

I have been emailing Will @ RSI but wasn't lucky to get a response.

Has anyone seen this? What might be causing this?

First thought is a ground not seated or making good enough contact. Otherwise I would wonder about to many amps on too small of a wire. No expert here. Just things I have seen before.

Hey thanks. I didn't check the grounds. I'd probably take a look and see how those are doing.

I thought about the wires being small and thought about upgrading them and maybe separate each relay. But then I think, this is what was provided by RSI and it's part of a kit. I don't think that they missed this or didn't test it !

I have same system and it works really well, none issue but I can check today later if wires get hot when pumps on.. I'll let you know..

I would suggest you contact Racetronix about putting together a custom harness with larger gauge wire and 40 amp relays.

:cheers:

RSI is very sweet system and I was happy with the stage 3 with dual DW pumps until I upgraded to tripple walbros :(

I took it out now as two walbros pumps failed and decided to move to ECS fuel system :)

I hope your issues will be sorted out fe9! good luck

wow on the third system now!? I hope it works for you!! I know how frustrated that can be...... GL buddy!

Sorry late answer.. Checked it and no wire heating on my car..

Good luck with the new fuel system. Why did you give up on the RSI system?

That's really good to hear :cheers:

Guys this is really getting serious. Today I fired up the car and let it idle for around 10 minutes and I started smelling like something was caught on fire. Take a look at the below pictures

http://i161.photobucket.com/albums/t.../WP_000107.jpg

http://i161.photobucket.com/albums/t.../WP_000106.jpg

http://i161.photobucket.com/albums/t.../WP_000105.jpg

http://i161.photobucket.com/albums/t.../WP_000104.jpg

The RSI system comes with it's own wiring kit and Harness that you just plug in the factory wiring. What could be the problem? I checked the ground and it is where it should be according to the RSI manual.

:ack:

Harness assembly components, process / QC is questionable.
For starters make sure the fuses are Bussman or Littlefuse brand only.
Burnt terminals MUST be replaced.

:eek:

Fe9 Fe9 be careful man.




Why didnt upgrade to Triple DW Pumps?
ECS is super nice too. :thumbs:

HOLY SH*T!! I'll recheck mine today.. just in case..

And Will do not answer anything??

Looks like the problem is to much amperage to run all three pumps threw that little gauge line & fuse. Why keep replacing it until it catches fire ? you need to address the problem ...

I'd re-wire everything with larger gauge wires and new fuse/ relays to be safe. What gauge wire are those?

So the red wire is running two pumps and are the two running continuously? I have a Racetronix harness with the fuse up'ed to 30A (I think) running my two Walbro 255's full time. I guess I should check my fuse holder but I don't believe it is a problem. The Racetronix harness seems like it is thicker GA wire than what you are showing there. Your red wire looks like ~14GA?

I have a racetronix harness on the stock fuel pump now and will be putting in my stage 3 RSI system this week. I haven't even looked to see if I can keep the racetronix harness feeding it or how it wires up.

Good luck.

None warming after one hour ride..

Sorry Will has been unavailable. fe9_fe9 pm sent.
If anybody has any questions or need anything feel free to pm me.
Thanks Billy