Fusebox question (pic included)

[JeremyL]

I got the blade type fusebox from TC. My old fusebox looked rough but everything worked (for now). I got the fusebox today (THANKS TC!) and was looking at my old fusebox before I started. Here's a pic of it: (click to enlarge)



It's pretty obvious that this isn't the original fusebox and is some kind of fuse panel that has been cutdown. My question is, isn't there something going on with the MAIN fuse? I mean that's it in the lower left hand corner right? Fuse is there but sholdn't the two screws below has wires connected to it? If so, I guess it was moved. I have 4 fuses in this old fuse box as you can see and I thought there was 4 factory fuses plus a main. Before I start trying to track down some weird Main fuse hidden somewhere under the seat or on the frame somewhere, I was just wondering if there really is 4+Main or if it's 3+Main. Because if it's 3+Main then I guess my main has been redone into this redneck fuseblock I have on there now. I was going to move my main to the new TC fuseblock but now I'm not sure where it's at.

[dpotter58]

that's an auxiliary fuse you can wire into handle something yourself like a radio...
The main is on the other side of the bike in a black rubber holder. big red wire black fuse holder.

[JeremyL]

Ohhhhhhh I see. I always wondered where this aux fuse was that people were talking about. And since my fuseblock wasn't stock when I got it I thought maybe someone already wired the main into this block. Is the main behind the other sidecover or should I be looking somewhere else?

Also, since I've already got a thread going, is the fuse that has 2 wires connected to one side (1st used fuse from LH side, top) normal? Is is something rigged up? Everything works on my bike, electrically anyways, but I hate when people mess and rig up wiring on a bike or car. Especially when they do a sloppy job like this.

[jetmechmarty]

The lower left is the AUX fuse. That's where you hook up your cell phone charger. The 30 Amp fuse is the main one and will have the fatter wire going to both sides of it. On my bike it's the thick red wire.

I have an SG. Its main fuse was under the left side cover. (I moved it.) I believe your SF may be different and have it in the box. Someone else here can give you a better answer. Pictured is my TC fuse box installation.

[jetmechmarty]

Looking at your photo, the main fuse is on the right with the fat red wires. The fat brown wires are the signals. No telling why you have two wires on that one fuse.

[JeremyL]

Looking at your photo, the main fuse is on the right with the fat red wires. The fat brown wires are the signals. No telling why you have two wires on that one fuse.

I haven't went outside to check the bike to find the Main yet (I'm at work) but you are saying you think my Main is already on this old block, on the far right? I was wondering if those were bigger because they were headlight or ignition or something and wasn't sure if the Main was going to be huge like 8 gauge wire or something.

Also, do you know if I should have 3 fuses, not counting the main? I was wondering if I was supposed to have 4 but someone doubled up on that one so now I have 3+Main.

Also, both of the pics you posted aren't showing up for me because I'm at work and our Internet filter blocks most image sharing sites... took me a min to find one that wasn't blocked so I could upload my pic. So in case you're showing me something important I can't see it at all so don't think I'm crazy or ignoring a pic you've posted.

[jetmechmarty]

You should have four fuses. (including the main) I sent an F wiring diagram, so that should be very close. I also sent a photo of my SG fuse box installation. You should have something to work with, but you really should have an SF wiring diagram.

[JeremyL]

Ok I remembered that I had two PDF copies of XS1100 manuals... One OEM and one that wasn't labeled but looks like it could be a Haynes or Chilton or something like that.

Here's what I looked up and copied:



This one is copied from the original user manual (except the part I typed in from the key that was on another part of the page) and it shows that the color scheme for mine is correct except that oddball line that is doubled.



This part is copied from the aftermarket manual and mentions that the 79 SF only has 3 fuses + a main so I think that answers that.



This was copied from the end of the aftermarket manual where every single year is separated. This was copied SPECIFICALLY from the 79 SF section so I'm pretty sure it is right. It shows the main by itself (but still in the fusebox I think) and the other 3.


I think I answered my own question but wanted to update the thread and confirm with you guys.

[XSive Okie]

Hey JeremyL, I sent TopCat a pm about one of his fuse blocks, but haven't heard back. How much was it with shipping and all. I'm looking to update my electrical mess that the PO had going as well.

[jetmechmarty]

Above is from the SG parts manual. Note item 36/37 is the main fuse for that bike.



Above is from the SF parts breakdown. I don't see a separate main fuse, so I think it's safe to assume it's in the box with the others. Listed are 2 30 amp fuses, 2 20 amp, and 3 10 amp fuses. There is a spare for each, so the box has 1 ea 30a, 1 ea 20a, and 2 ea 10a.

[JeremyL]

Hey JeremyL, I sent TopCat a pm about one of his fuse blocks, but haven't heard back. How much was it with shipping and all. I'm looking to update my electrical mess that the PO had going as well.

He's still selling them. I was afraid he wasn't since many of the fuseblock posts are from a while ago but I PM'd him and he sent me an email with an address to use for PayPal. Sent him $10, shipping and all, and that included the crimp on connectors! Best deal in XS11 history! He's a great guy for helping us out with this and not marking it up 5x. If I was to go to a parts store and bought a simple fuse block then bought a pack of connectors (probably like $5.99+) I'd have $30-40 in one. I was surprised by the price. And with my 79 SF having everything all in one place I should have it installed in 20 min. I should've done it a long time ago.

[JeremyL]

Above is from the SG parts manual. Note item 36/37 is the main fuse for that bike.


Above is from the SF parts breakdown. I don't see a separate main fuse, so I think it's safe to assume it's in the box with the others. Listed are 2 30 amp fuses, 2 20 amp, and 3 10 amp fuses. There is a spare for each, so the box has 1 ea 30a, 1 ea 20a, and 2 ea 10a.

yay! I'm glad mine is right there so it's one less thing to have to do. Might need to trace down that one oddball white wire because it's obviously not stock. The bike doesn't have anything extra added on now so I'm not sure if it's something that's been rigged up or if something was added before and isn't there now.

[DGXSER]

Yes, all of the 78 and 79 bikes had the main included in the main fuse panel. The 80-81 models moved the main to the left side in that separate holder.

Two red wires is the main, Same tan wire splits into three to feed the other fuses. Now, the connectors TC sells are tough little buggers, so get some good pliers to crimp on them with! I have fixed a couple bikes where the owner had a new fuse box from TC and ended up not getting a good crimp making poor connections.

[JeremyL]

Yes, all of the 78 and 79 bikes had the main included in the main fuse panel. The 80-81 models moved the main to the left side in that separate holder.

Two red wires is the main, Same tan wire splits into three to feed the other fuses. Now, the connectors TC sells are tough little buggers, so get some good pliers to crimp on them with! I have fixed a couple bikes where the owner had a new fuse box from TC and ended up not getting a good crimp making poor connections.

Thanks for the confirmation. TC sent me an email warning me about how tough the connectors are and recommended using vise grips (set with a 1mm or so gap) to crimp them down. I'm very picky about wiring after installing a few car stereo systems and such and leaving these crimp on connectors loose drives me crazy. I'll definitely make sure mine are on very tight but also not so tight it ruins the connector and makes it just as loose.

Hoping to try to wire it all up tomorrow. Since all 4 fuses are right there together it should be pretty quick to install. If I had a garage I'd do it tonight but since I have to work out in the drive the rain and darkness slows me down

[JeremyL]

Ok I couldn't take the suspense anymore and ran out before it got dark and did the fuse box. I bet I had it done in 20 min and that was taking my time. I'm no stranger to wiring or crimping so it didn't take long and the ends on the wires are rock solid. Did a little mod to the ears on the box to make it work with my existing holes but probably didn't spend 5 min on that and its screwed down solid.

Only problem is I forgot that I didn't have any fuses So I couldn't test it but I can't imagine it not working. If the nasty mess worked before for the past 2 years I think this will work great.

Here's a pic:



Sorry for the fuzziness it was getting dark so it was hard to see on my phone

I wasn't sure what that oddball wire went to but just to be safe (and since I didn't have time to trace it down) I just stuck it in with the other wire it was joined with. On the other skinny wires I doubled them over to fit in the crimp end better but on that one I didn't of course.

And those crimp ends are TOUGH. I used some big vise grips and did them twice and pulled pretty hard and they won't come out so since they're just sitting there they'll be fine. But you definitely couldn't crimp them, at least easily, with a regular pair of pliers or anything.