when i went out to start my truck this morning, it cranked over just fine but wouldn't fire up at all. i remembered how in the days before the electric pump, it would crank till the batteries almost died before coming to life, so i gave it a couple 30 second periods of cranking with a good break between them, but still no life. after the third such cycle, i knew something was up.
the WTS light cycled normally, but i wasn't getting power to the plugs. on closer inspection, i wasn't getting power to the battery side of the GP controller. i checked the wires from the battery at both sides of the connector that usually melts down, and had power in and out of it, but no power at the controller.
to get it going, i ran a temporary 4ga wire straight from the right battery to the GP controller, and it fired up on the first cylinder up.

so, is this a fairly common failure, or not? i know the fusible link or the connection i checked at are likely failure points, but they tested ok with a test light. any other failure points in the harness?

lets say i run a new wire to it, what size fuse and wire would be advised? or skip the fuse and just run a wire?

 

I recently did this to my truck. I got two fusible links and soldered it to 6ft of 6ga wire and put a crimp on ring on the end with the gp relay. I did this because my connector melted.