69 912 new engine+starter blowing fuses when trying to start
 

We've recently gotten our 1969 912 back on the road. The engine was rebuilt, we've rebuilt the carbs, and basically wrapped up a 10 year major resto. After some recent issues with the starter, we replaced it, and now find ourselves blowing a fuse almost every time we try to run it (especially when hot).

Green and Red light come on, car may turn over once (or just pop fuse - 2nd and 3rd fuse down from top), or it will turn over a few times with what sounds like some hydrostatic compression built up and then stop turning over.

After we let it sit for a while, 50% of the time it will turn right over, start and run.

I'm afraid to take the car anywhere where I have to turn it off for fear it won't restart.

I've checked and sanded down the terminals in the fuse box to make sure good contact. Any other ideas?

Thanks!

1. check your wiring
2. The battery goes to 1-5 on the #1 fuse box.
3. The 2 fuse wire goes to the ignition switch.
4. The 3 fuse wire only goes to the Cigar lighter and the light in the glove box.

So it's a good chance if the wiring is correct and there is not a short in the wiring. Then it may be the ignition switch.

Fairly common issue, try here.
912 Board - Search

Thanks guys for the quick response. Any reason by chance why the fuse wire for #2 and #3 would be bridged together? I noticed a wire bridging them.

Really random in that sometimes it starts strong, then the next time it turns over, makes an ugly noise and fuse #3 blows. Thanks again!

912 wiring configuration - image
 

http://forums.pelicanparts.com/uploa...1314571645.jpg

This is a picture of the wires

You need a wiring diagram for the 912 and one for the 69 911. The 69 used two fuse blocks where the 65-68 used one. They never did make a wiring diagram just for the 69 912.

If you do not have a wiring diagram for both cars. You are just spinning your wheels.

I am not an auto electrician but, on a 69, I believe that fuses 1 and 2 were not used. They are for electric window lifts on some 911 models.

Fuse holders 1,2,3,4 and 5 should all be live with the ignition off. They are fed from the battery. Fuse 3 serves the cigarette lighter relay, the electric clock, the glove compartment light and the interior lights (operated by the door switches, etc.). It seems that someone has put a fuse into 2 and jumpered its downside to the downside of 3. Can only presume they wanted belt and braces. Perhaps the clock was stopping - known to happen! - and they wanted to be sure it was not a poor connection at the fuse.

My skin crawls when I look at the stock wiring. There are 3 or 4 wires under each terminal how do you know which wire could be bad. When I had my car down for restore I completely rewired the fuses. I put in a terminal block with 30 spots every wire has its own test point. And a updated fuse block with 16 instead of 12 fuses. The best diagrams I found were at Dave Hillmans 912 web page.

Wiring Diagram for Early 912

Good luck

you have a wire prob for sure,

if your stuck get an Auto Elctrican it's not worth the hassel they will work in out in a few hours and tidy up the rest.. if your not carefull you could start a fire..

but just check you have the right fuse rated fuses in place.. after than get the yellow pages out and ring about..