Fuse Panel

[Jdwags]

Ok here is the repost,
and the the response I already received from the other list.

I need to replace the fuse panel to correct one of the many woes from the po, some may remember my post 2 weeks ago about literally smoking the ign wire from the switch to where the po hard wired (no fuse) it into the system... the only thing that saved me was a poor connection melted and thus became the fuse.

I know that Indy rick used to do panels, and others have used different things, I'm still trying to beat the clock again for Big Island Deuce.. and i also think i have to replace the ign wire, but not sure if i have to split the harness due to any splices???

(one reply as follows)


> On Sat, 6 Jul 2002 15:35:34 -0700 "Michael Hart" <mdh@s...>
> wrote....
>
> Begin Quote:
>
> > Jeff, I got one from Schuck's for like $4. Next time you're over have
> > a look at how I did the XJ's fuse panel. It fit under the stock fuse
> > cover too ;>)
>

From Homer Parker:

> You wouldn't have any pictures of it, would you? I've got nylon tie-wraps
> in use at the moment, and think I might want something a bit more
> permenant.. Was thinking about using in-line spade fuse holders, but am
> open to other ideas..
>
> ---
> Homer Parker (The Bogus One)
>
> http://www.homershut.net
> telnet://bbs.homershut.net

[sixtysix]

Here are 3 different ways I solved the fuse panel problem....

This was one I made for Ron Lymans bike, it uses cheap inline fuse holders and uses the larger size modern fuses, the original base is flipped over and the holders are fastened with very small zip ties.


This next one is one that Rick Jemison sells for an XS, it comes as a kit with the fuse block and etched base. Since different years have different fuse configerations, one side is etched for a main and the other is not. (my 80 has a main on the leftside in a holder byitself). Fuse block is shown in a 79SF that I rebuilt.


This next one is the one I redid on my 80, again the old block was flipped over and the holders are held on with little zip ties. On this one I used waterproof mini fuse holders. These take the very small modern type fuses. First picture shows all holders closed, next ones shows two holders open to reveal fuses.




Gary

[Jdwags]

splice connections

Ok, kewl Gary,

just to confirm common sense, (ive been lacking lately)

the splices into the wiring are soldered and heat shrinked...
oh wow, i got some work to do to fix this spagetti left over by the po

thanks for your help Gary and all

[sixtysix]

No actually I never use solder unless there is no other choice, it weakens the wire and makes it more prone to breakage. I use Amp knife connectors on all my wire splices, crimped with an Amp crimper these connections are gauranteed for life.

If you are really interested in these connectors here is a link to the instruction sheet that comes with the connectors. You will nee acrobat reader since it is a PDF file.

http://catalog.tycoelectronics.com/T.../21/159122.pdf

Gary

[CA.XSer]

[QUOTE]Originally posted by sixtysix
[B]Here are 3 different ways I solved the fuse panel problem....

Gary
Thanks for posting the info and pics. Gives me some great ideas to replace my inline fuses from the PO.

[sixtysix]

Glad I could help !

[Jdwags]

Horray !!

Well,

I found that the soldered splices the po did were all bad, so i used what i had for now, and cleaned and redid the connections.

also found another in line fuse that was not connecting well, I replaced it, and put a fuse in the non existant 30 amp main line.
the reason it fried was apparently a bullet splice behind the spagetti in the blue wire from the ign switch grounded... which went everywhere...
the 30 amp main had a 16 gauge splice but no fuse in it, so the 16 gauge wire melted, i guess he must have been thinking like a fusable link or something

got to go get some grease for the plug, but cleaned it as much as i could.. But IM Back UP AND RUNNING, such as it is..

[Mike Hart]

re: Hooray!

Alright, Jeff, great

Want to come over this afternoon to see how I did the XJ?

[Jdwags]

fuse

wish i could, tied down with the 3 kids, at the moment,

perhaps this next weekend, I'm hoping to get a little carb work done this time

[Bill]

Here's a picture of my fuse block replacement:


and, if anyone's interested, here's the label from the package:


I did the mod a couple of years ago with no problems since. Very worthwhile. The originals all go bad eventually from brittle fuse clips. Nobody needs that out on the road, far away from home! Best to fix them before they cause trouble...

Bill

[scsherer]

fuses

How come nobody is mentioning the fuse box from JCW? I put that one in my 78 and it was fairly easy and works like a charm. The po had wired everything together, so I feel better now!
Stan Sherer

[Skinny Biker]

Fuse block pic

Here is a link to my photo section where I haveposted this pic of my fuse panel replacement... Came out of a CBR600 and fit like a dream. Of course, I did not do the wiring work, as my bike still runs, but did not take my mechanic friend long to tie it into place...

http://us.f1.yahoofs.com/users/1b1d0...0+in+XS11.jpg?

[Skinny Biker]

2nd attempt to post the pic...

[Jdwags]

skinny, your fuse pic

My goodness that looks clean and good...

can't say my temporary fix is anywhere near that nice.

in fact. im hoping i can keep the side cover together and on the bike long enough to cover it for Deuce...

dont want to be a total rat bike...

[sixtysix]

Dennis....1 of two things, either yahoo does not allow pictures to be directly acessed like this (to limit bandwidth) or this forum does not like the + ? . and other characters in your picture URL, other than that you did it right.

Gary

Originally posted by Skinny Biker
2nd attempt to post the pic...