Topic: Cheap and effective fuse box/fuse holder replacement.

[liaudio]

This is posted in the tips/tricks section as well.

Are you having fuse blowing problems because your fuse holder is old and dingy?

We all know how notoriously lousy the stock Fuse holder / fuse box is.  If they are old, the connections get really corroded, can melt the plastic, and even have a possiblitiy of an electrical fire.

In my experience, I have ditched the stock fuse holders all together.  I never liked those cylindrical fuses either.

What works amazingly well is to just cut the wires and crimp on female spade connectors to the feed and draw side.  Then take an appropriate 12v blade type automotive fuse and put that in-line.  Viola!  Cost? About $2!

It not only eliminates the fuse-box, but you can eliminate the connector clip that connects the fuse box to the main wire harness as well. My theory is: eliminating electrical connectors = less resistance = higher voltage. 

I relocated all my eletronics under the seat, so these pictures will look a little different than stock configured bikes.

[MoTo-BunnY]

Wow. . .kewl idea. I was trying to fit those individual fuse holders in there and having trouble with it. Those look like they take up a lot less space - flatter. Those kind of fuses are way easier to find, too.

[Rsnip988]

thank you for this genius idea, i did it myself, saved a lot of time money anbd space

THANK YOU


RKS

[cben750f0]

thats cool, i did this, though it was $12 aud... makes a huge difference though!!!!... thanks for the heads up...
http://www.sohc4.us/forums/index.php?topic=313.0

peace

[luvhonda750]

Thanks, this is a very nice fix, I was going to spend 20.00 on ebay for another one that may have been broken.

[nteek754]

Hey all  a few years back I did this I bought some circut breakers and took an old worn out stock fuse box and wired in the  breakers all you have to do is  cut out the box leaving the six wires at three differant lengths  put some crimped eyelets on to the wires and bolt the  breakers on with  the little nuts that come with them  tape them up and bingo no more blowing fuses just use the right amps I had an  issue with my brake light  (I put one up on the back of sissy bar) well comeing to a stop all of a sudden bike would die  I would look down and my dash lights would be on she would fire back up and off I would go finnaly after picking up a pair of boots at the cobblers and stapping them on the  rack I saw the bare wire culprit  at the time I only had two circut breakers so one of them was doubled up but that setup worked for years  and as Im typeing waiting for delivery of some new 10 amp breakers  hope this helps have fun Craig in Maine

[mark]

I liked the ideas above - using blade fuses and eliminating the extra connection to the main harness.
I liked moving the fuses to under the seat even better - saves tugging on that delicate side cover!
The harness connector was in pretty good shape, however - and I didn't want to cut up the harness.
I removed the female terminals from the plastic harness connector, cleaned them with a small wire brush, gave a gentle squeeze with the toolkit pliers, and applied some bits of heat shrink tubing. Plugged in the fuses and covered the mess with a rubber relay cover from some car at the junkyard. My spare fuses sit atop the airbox with the toolkit.




Happy trails.

[riktaboy]

It's amaazing how such a simple thing that should be so obvious to do, slips right by you.  What a great idea, thanks for sharing it.

[neil young]

I liked the ideas above - using blade fuses and eliminating the extra connection to the main harness.
I liked moving the fuses to under the seat even better - saves tugging on that delicate side cover!
The harness connector was in pretty good shape, however - and I didn't want to cut up the harness.
I removed the female terminals from the plastic harness connector, cleaned them with a small wire brush, gave a gentle squeeze with the toolkit pliers, and applied some bits of heat shrink tubing. Plugged in the fuses and covered the mess with a rubber relay cover from some car at the junkyard. My spare fuses sit atop the airbox with the toolkit.




Happy trails.
[/quoteother than shrink wrap and some fuses was then anything else you had to purchase for this project....which buy the way is a great idea

[mark]

other than shrink wrap and some fuses was then anything else you had to purchase for this project....which buy the way is a great idea

That was it. About 9" of shrink tube and some fuses - stuff I had lying around anyway. I think the cute rubber bootie was a Toyota part - Nissan maybe? That was a freebie from the boneyard.

My fuse box was melted to crap. I left it in there just for looks - in case I pull the cover for some OTHER reason!

It'd sure be nice if I could fix the carbs that cheap.


Happy trails.

BTW.. At the yard, I was looking at some 8 pole connector plastics that the Honda terminals would snap into.. (with the wires paired side by side to make a 'fuse block' ) All needed a bit of plastic removed between the terminals to plug a fuse in fully. I may try that in the future.