Fuse Box Replacement

[oseaghdha]

Anyone ever see this?
Note the scabbed on inline holder for the headlights and the stripped twist tie holding the ignition fuse. YUCKY.




Step 1: Get it out of there. Two screws and swing it up and out of the way.





2. Install TC's fuse box.
I used a hacksaw to slot the right side. I also notched the top corners to clear the large screws and to get it centered as much as possible top to bottom.



I center punched for the other hole, and drilled it.
Flat washers add strength and hide my sloppy work.




Cut the wires out of the old box and label them.




I stripped back the tape and separated the top wires from the bottom ones.
Retape the bottom wires and run them through the metal loop.




I attached the wires using the right angle connectors recommended by Hobbyman.
I soldered them, crimped and applied shrink tube.




This thing is the $hit! Runs on butane.
It heats in about 15 seconds and includes a torch tip.
There was a thread about traveling tools including a soldering iron. This is perfect.



From the Shack.
You can see the connectors also from RS.




All done.

[mro]

Nice job, looks good

I've had one of TC's fuse boxes for a while but have not had any problems with my OEM's so have yet to install it.


mro

[cajun31]

Looks great

how much did all the parts cost you and how long did it take you to do the conversion?

[oseaghdha]

Re: Looks great

Originally posted by cajun31
how much did all the parts cost you and how long did it take you to do the conversion?

I got the fuse box from TC for I think $7. The connectors and soldering iron were about $29. Just the connectors were probably $3, I dunno, I wanted a new toy.

I could have finished it up in maybe three hours, but I wasn't in a hurry because the bike is down for parts right now.