I just blew my fourth fuel rewire relay yesterday.

[90 GSX]

I went through three of those Bosch 30A radio shack relays before I ordered a chunky 75A bosch relay online with screw on terminals (basically, it was a beefy relay, way beefier than required to power a walbro 255). That one just blew last night while driving at 65 mph on the freeway. What is the deal here?

 

[blcknspo0ln]

I would assume you have a bad ground. Go back to your 30A inline fuse and create (don't clip off) a second ground from your existing ground wire. Sometimes that's the trick.

p.s., I wouldn't use a bigger amperage'd fuse just because the smaller ones blow. That is a sign of a poor electrical system and by putting in a 100A fuse will only bandage the problem.

 

[bling5tatus]

I think blcknspooln nailed it... I thought bad ground just by reading the title before I actually read the thread. Let us know how it turns out after you fix the ground... also, how long is it taking to blow the relays?

 

[90 GSX]

I'm not talking about the fuse, I'm talking about the relay that activates the fuel pump circuit. The 30A fuse next to the battery has not blown one single time.

I'd say the radio shack ones lasted anywhere from 3-5 months. This 75A one lasted for only 2 months.

I will check the relay ground and make sure it's tight contact on bare metal.

 

[blcknspo0ln]

My mistake about the relay, I still think it is a bad ground, however.