Fuse Block replaced and all is well


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Wingsconsin
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Fuse Block replaced and all is well

Postby Wingsconsin » Wed Oct 24, 2012 8:39 pm



In a previous thread I stated the fuse block on the 1980 Interstate was heating up, and the lights were cutting out.After investigation it was determined that the resistance due to corrosion caused fuse to over heat, get loose, and actually melt plastic.

See this thread for details --> viewtopic.php?f=4&t=14207

Now the replacement is done and the fuses are all automotive style blade fuses --
Finding a fuse box that had a input bus for 4 lines was nearly impossible so I made my own version...


I crimped and soldered and shrunk tubed and electrical taped it...Not pretty as my soldering skills are suspect at best...but very functional...!

I simply removed each wire 1 at a time and reconnected them to the new fuse box...



Eventually I got them all moved to the new box...The barrier strip on the right is for auxillary hook ups...right now the handlebar Cb is hooked up and there are places for more things as well as long as they are low amperage. The 7.5 amp fuse shold be fine to handle almost anything I want to add as an accesorie...



After a good 75 mile test run all is well and things are even better...

Headlight is brighter - Horn is louder - Turn signals flash faster - bike seems to run better (placebo effect?)

And I found out this was a fire waiting to happen as well..
The fuse block once it was out of the bike ...




Postings are my opinions based on experience and acquired knowledge.
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Re: Fuse Block replaced and all is well

Postby WingAdmin » Thu Oct 25, 2012 6:55 am

Excellent job! Do you have more than just electrical tape (i.e. shrink tubing) on the fused side, or is it just electrical tape on those wires?

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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Thu Oct 25, 2012 8:45 am

WingAdmin wrote:Excellent job! Do you have more than just electrical tape (i.e. shrink tubing) on the fused side, or is it just electrical tape on those wires?


All wires (except the 4 'bus' red wires which do not have the top layerof tape) are
- crimped - soldered where I could - shrink tube wrap - tape
Most of the electrical tape I put on to act as a protective barrier - like a 'skin'
I have a lot of confidence in my crimps and the shrink tube - I've use them on my 1500 for 10,000's of miles already
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Re: Fuse Block replaced and all is well

Postby WingAdmin » Thu Oct 25, 2012 10:36 am

Wingsconsin wrote:All wires (except the 4 'bus' red wires which do not have the top layerof tape) are
- crimped - soldered where I could - shrink tube wrap - tape
Most of the electrical tape I put on to act as a protective barrier - like a 'skin'
I have a lot of confidence in my crimps and the shrink tube - I've use them on my 1500 for 10,000's of miles already


I think you'll have no problem at all with those for a very long time.

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Re: Fuse Block replaced and all is well

Postby littlebeaver » Thu Oct 25, 2012 11:28 am

Oh man, first of all thank you for a great post, many many members will love this post, it's a really good fix...Once I got a used XS 1100 Yamaha nice bike, I rode it everywhere one day it just quit, got it home and went thru the electrical system, the freakin fuse box man, the clips were bad and the one to the ignition just fell apart, I never even looked there before but, I didn't know what to do so I went down and bought a inline fuse holder for every line in the box ha ha :lol: :shock: , I got my wife's labeler and labeled every wire, soldered connections and thru the box out...It worked fine but there's nothing like a new box like you did...Good deal...Bravo

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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Thu Oct 25, 2012 1:06 pm

Thanks for the kind words...
2 things occur to me to mention for those who would do this to their bike.. :geek:

1) The black side wires all go from the OEM connector - under the fuse box mounting plate - to connect with th ebottom side of th efuse block. The Red side wires all connect from the top side and go directly from the connector to the fuse block. In order to do this I had to extend the black wires about 4" so they would reach and make the turn back to the box. Tucking them under the monting plate hides them and keeps thing organized in my kind...and that is one reason I shrunk wrapped, AND electrical taped them..to keep the wires clean and dry and safe from edges that might fray the wires

2) Still working on the LABELING part of this....Just having the old lid to work with will help me get it right...but I would like it to be neat and organized as well....this is my sons Goldwing and when he gets back from college he will be riding it (a lot) next summer so I feel I should make it as clean as possible so he can diagnose any potential problems should they occur.
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Re: Fuse Block replaced and all is well

Postby portugeezer » Thu Oct 25, 2012 6:33 pm

I don't live that far from you. If you ever need any kind of help hit me up! I fix guitars and my soldering is pretty darned spiffy!

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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Thu Oct 25, 2012 7:30 pm

portugeezer wrote:I don't live that far from you. If you ever need any kind of help hit me up! I fix guitars and my soldering is pretty darned spiffy!


Thanks for the offer - we should get together sometime anyway next summer - where I live there are some pretty nice rides...

What I think I will need some time in the future is a carb expert...But I am still trying to sort that out...and the riding season is nearly over so testing is difficult...LOL...(Plus I need to get tires soon)
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Re: Fuse Block replaced and all is well

Postby mcbrayer3rd » Fri Oct 26, 2012 7:06 pm

this is just what i was looking for!!!!!!!!!!!!!!!!!!!!!!!!
McBrayer3rd

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Re: Fuse Block replaced and all is well

Postby bdukes » Fri Nov 30, 2012 6:23 pm

Where did you get the fuse box? Do you have a parts number for it.

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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Sat Dec 01, 2012 12:02 am

bdukes wrote:Where did you get the fuse box? Do you have a parts number for it.



http://www.amazon.com/Auxiliary-Automot ... fuse+block
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Re: Fuse Block replaced and all is well

Postby bdukes » Sun Dec 02, 2012 9:08 am

Thanks I look at NAPA and they didn't have that one.They wanted $35 for a square one.Ordering from amazon now.

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Re: Fuse Block replaced and all is well

Postby busarider007 » Sat Dec 15, 2012 9:11 am

Nice work. I also have been looking to update the fuse block..

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Re: Fuse Block replaced and all is well

Postby sparrowhawwk » Sat Dec 15, 2012 7:07 pm

Thanks for giving me the incentive to get mine changed also. Aside from the fact that the blade fuses are a lot nicer to use, changing them over and cleaning up the wiring might just be one more step in making the old bike run a little better. :D

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Re: Fuse Block replaced and all is well

Postby sparrowhawwk » Tue Dec 18, 2012 11:00 am

Haven't had time to look into the details but a supplier we use has some nice fuse blocks with covers in 4,6,8 and ten fuse sizes. Don't know what they show on line but the company is Waytek. www.waytekwire.com The pictures in my catalog look good.

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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Wed Dec 19, 2012 10:42 am

sparrowhawwk wrote:Haven't had time to look into the details but a supplier we use has some nice fuse blocks with covers in 4,6,8 and ten fuse sizes. Don't know what they show on line but the company is Waytek. http://www.waytekwire.com The pictures in my catalog look good.

There are a couple of nice looking fuse blocks in there which I think would work pretty well...
http://www.waytekwire.com/item/46082/FU ... ---8-FUSE/

This one seems to hold 8 fuses (2 more than you need) and has 2 -- 4 place covers...

It seems the purchase QTY may be 10 minimum...? That would be a challenge I guess...
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Re: Fuse Block replaced and all is well

Postby sparrowhawwk » Wed Dec 19, 2012 12:05 pm

I think they could be ordered individually. I can get them that way, or at least I have before.

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Re: Fuse Block replaced and all is well

Postby patbrandon1 » Mon Dec 31, 2012 5:36 am

Hi Wingsconsin. Nice job. I have a questions for you. Actually a few. Where did you get the barrier strip? And how is the power to it fused? Does the power for it come off of the fuse block?

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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Mon Dec 31, 2012 9:23 am

patbrandon1 wrote:Hi Wingsconsin. Nice job. I have a questions for you. Actually a few. Where did you get the barrier strip? And how is the power to it fused? Does the power for it come off of the fuse block?


The small barrier strip on the far right is from Radio Shack -- They have several choices for sizes and the jumper strips as well to connect several positions together either hot or ground.
If you look closely at the pictures you will see the far left fuse is the AUX fuse. I put in a 7.5 AMP fuse (up from the 5 AMP previously in there) and connected the aux fuse to the barrier strip so I can attach more accs if I want to...
Right now the only thing on there is the J & M Handlebar Mounted CB system....
Postings are my opinions based on experience and acquired knowledge.
Your results may vary. Universal disclaimers apply.


Motorcycle Adventure Storys writen by me
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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Mon Apr 15, 2013 8:34 am

Wingsconsin wrote:
patbrandon1 wrote:Hi Wingsconsin. Nice job. I have a questions for you. Actually a few. Where did you get the barrier strip? And how is the power to it fused? Does the power for it come off of the fuse block?


The small barrier strip on the far right is from Radio Shack -- They have several choices for sizes and the jumper strips as well to connect several positions together either hot or ground.
If you look closely at the pictures you will see the far RIGHT fuse is the AUX fuse. I put in a 7.5 AMP fuse (up from the 5 AMP previously in there) and connected the aux fuse to the barrier strip so I can attach more accs if I want to...
Right now the only thing on there is the J & M Handlebar Mounted CB system....


Correction
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Re: Fuse Block replaced and all is well

Postby ram11397 » Sat Jun 20, 2015 9:21 pm

Hi
I know old post but doing research and this is very close to what i want to do. My question the underside of the OEM fuse block as that bar with just one wire connected to it that's what it looks like to me, what did you do on the new one? spiced 4 wires off the one wire on the OEM ? hope this makes sense when it comes to electrical i am dumb as a bag of rocks!!!

Rick
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1982 GL 1100 Aspencade

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Re: Fuse Block replaced and all is well

Postby patbrandon1 » Mon Jun 22, 2015 10:41 pm

ram11397 wrote:Hi
My question the underside of the OEM fuse block as that bar with just one wire connected to it that's what it looks like to me, what did you do on the new one? spiced 4 wires off the one wire on the OEM ?

Rick


Hi Rick. I'm pretty sure your Aspencade has a bit different wiring, but pretty close to my Interstate as far as the fuse block. Maybe the photos of mine finished will help. But the very first post to this topic has a pic of 4 wires coming off of one. So to answer your question as far as I can understand what you are asking, Yes, I made four off of the one. The two wires on the right side of the block come from the ignition switch independent of the four. One for the park position of the switch which will activate the rear running lights, and the other is from the accessory, on, and park positions, where you can ad other things like radio, fog lights, or whatever.



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ram11397
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Re: Fuse Block replaced and all is well

Postby ram11397 » Tue Jun 23, 2015 1:17 pm

Hi,
Yes that was what i was asking. Also pictures help
thanks
Rick
Rick
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Wingsconsin
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Re: Fuse Block replaced and all is well

Postby Wingsconsin » Tue Jun 23, 2015 1:25 pm

ram11397 wrote:Hi
I know old post but doing research and this is very close to what i want to do. My question the underside of the OEM fuse block as that bar with just one wire connected to it that's what it looks like to me, what did you do on the new one? spiced 4 wires off the one wire on the OEM ? hope this makes sense when it comes to electrical i am dumb as a bag of rocks!!!

Rick


That's what did..It is called a serial buss I think..but I just ran all 4 wires off the one with some soldering, and shrink tubing and red electrical tape. That bike is now sold to a new owner and down the road for a while already, but we rode the snot out of it for nearly 10,000 miles with out a problem ever with those fuses (finally).
Postings are my opinions based on experience and acquired knowledge.
Your results may vary. Universal disclaimers apply.


Motorcycle Adventure Storys writen by me
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ram11397
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Re: Fuse Block replaced and all is well

Postby ram11397 » Tue Jul 14, 2015 11:09 pm

Hi again,
Was hoping you can remember i know the bike is long gone.
ordered and received fuse block my question is, looks like you attached the block to a piece of plastic/wood ? how did you attach it to the bike?

Rick


Rick
1982 GL 1100 Aspencade


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