Fuse Box Replacement: A Pictorial
by Xsive Dan/OSEAGHDHA

http://www.xs11.com/images/stories/fusebox11.jpg

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


http://www.xs11.com/images/stories/fusebox12.jpg

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

http://www.xs11.com/images/stories/fusebox13.jpg

http://www.xs11.com/images/stories/fusebox14.jpg

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.


http://www.xs11.com/images/stories/fusebox16.jpg
I center punched for the other hole, and drilled it.
Flat washers add strength and hide my sloppy work.


http://www.xs11.com/images/stories/fusebox17.jpg

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


http://www.xs11.com/images/stories/fusebox18.jpg

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.


http://www.xs11.com/images/stories/fusebox20.jpg

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


http://www.xs11.com/images/stories/fusebox21.jpg

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.

http://www.xs11.com/images/stories/fusebox22.jpg

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


http://www.xs11.com/images/stories/fusebox24.jpg
http://www.xs11.com/images/stories/fusebox25.jpg

All done.

Looks great
 

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

Re: Looks great
 

I got the fuse box from TC for I think $8. 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.

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Added by T.C.:

Addendum photos of folks installing in their XJ's. The sidecover doesn't have as much room, and will hit this fuseblock if it's mounted just on top of the OEM fuseblock metal plate, so folks have had to get creative with how they mounted them, most involve either removing the backing metal plate, or cutting sections out of it so allow the fuseblock to sit deeper towards the battery so the side cover will close!

http://www.xs11.com/images/stories/fuseblock_bne.jpg

http://www.xs11.com/images/stories/f...k_cobia_xj.jpg