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SECTION D:
ELECTRICAL SYSTEM:
--Electrical System Wiring: Fuseboxes
WIRING SYSTEM:
FUSEBOXES, FUSEHOLDERS, AND FUSES:
COMMENTS: your stock fusebox was marginal, at best, and that was 20+ years ago. Replacing it with a modern style fuse panel or in-line fuse holders such as the styles listed below in the Replacement Fuseboxes section will prevent frustrating, expensive, and potentially dangerous electrical system problems for years to come.
The following models used a fusebox utilizing four "glass tube" AGC fuses with one 20A main fuse, and three 10A fuses for the ignition, turn signal, and headlight circuits: all XJ550 models, all XJ650 models, 1983 XJ750 Maxim and XJ750 Midnight Maxim models, and the main fusebox on XJ1100 models.
These models used a fusebox utilizing four "glass tube" AGC fuses that contained one 30A main fuse, and three 10A fuses for the ignition, turn signal, and headlight circuits: 1982 XJ750 Maxim model, all XJ750 Seca models, and the XJ900RK Seca.
In addition, the following models used a separate single "glass tube" 5A AGC fuse, within its own small in-line holder, for the computerized gauge cluster: all XJ650 Turbo models, 1982 XJ750 Maxim, and all XJ750 Seca models. This fuseholder is certainly a candidate for updating with the 10A ATO style in-line fuse holder HCP7122 listed below.
XJ700 models used two separate fuse panels: one that contained the four secondary circuits, including two 10A fuses, and two 15A fuses, which is located within the instrument warning lights panel; and a separate 30A main circuit in-line fuse holder was located under the seat. These bikes used the later push-in style ATC fuses in the dash fuse panel from the factory; the 30A main circuit fuses were still the older "glass tube" AGC style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16777 listed below.
1978-79 XS1100 models use a single fusebox utilizing four "glass tube" AGC fuses with one 30A main fuse, one 20A signals circuit fuse, and two 10A fuses for the ignition and headlight circuits. These models also used a small “accessory terminal” which held a single 10A fuse, and which allowed the for easy installation of any accessory circuit that the owner which to create (or, for use with the factory optional front fairing).
XJ1100 an 1980-81 XS1100 models also used two separate fuse panels: one that contained four secondary circuits, which is located behind the right side frame panel; along with a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and both are certainly candidates for updating with the ATC style fusebox and fuseholder. These models also used a small “accessory terminal” which held a single 10A fuse, and which allowed the for easy installation of any accessory circuit that the owner which to create (or, for use with the factory optional front fairing).
ORIGINAL STYLE "GLASS-TUBE" FUSEBOXES:
If you're doing a "museum-quality" restoration, where every detail has to be period-correct, then you'll want to consider using an original reproduction FUSEBOX that is faithful to the original design, style, and appearance, right down to the included glass fuses!
These fuseboxes come with an already-installed 8-position plastic terminal block on the fusebox lead wires----and matching connector block and terminals for the harness side wires----which makes installation and maintenance tasks much easier. The entire fusebox can be easily removed from the bike, (or the entire airbox filter lid can be removed, on models that have the fuse panel screwed to the lid) since it's on its own little stub-harness now! If the original direct-wired method is desired, you can always remove the connector block, and tie into your original harness wires, using the butt connectors listed below. You will need 6 of the 18-22 gauge connectors and 2 of the 14-16 gauge connectors in order to convert these fuseboxes to a direct-wire application.
HCP11182 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for all XJ550, all XJ650 (except Turbo), and all 1983 XJ750 Maxim and Midnight Maxim models. Comes with original glass fuses (1 x 20A and 3 x 10A).
$ 59.95
HCP10444 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for all 1984-85 FJ600, XJ650 Turbo, and XJ1100 models. Comes with original glass fuses (1 x 20A and 3 x 10A).
$ 52.95
HCP24652 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for 1982 XJ750 Maxim, all 1981-83 XJ750 Seca and XJ750 Euro models, and all XJ900 models. Comes with original glass fuses (1 x 30A and 3 x 10A).
$ 59.95
HCP24654 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for 1984 XJ750RL Seca models. Comes with original glass fuses (1 x 30A, 1 x 20A, and 2 x 10A).
$ 59.95
HCP13045 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTOR, for wires that are both 18-22 gauge. Each:
$ 1.95
HCP13045SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTORS, for wires that are both 18-22 gauge. Set of 10:
$ 16.95
HCP13046 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTOR, for wires that are both 14-16 gauge. Each:
$ 1.95
HCP13046SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTORS, for wires that are both 14-16 gauge. Set of 10:
$ 16.95
HCP14606 OEM original fusebox FUSEHOLDER CLIP TERMINAL, fits into stock factory fuseboxes, crimp-on, open-barrel style tin-plated brass terminals fits all stock XJ-series fuseboxes that use glass fuses. Use 2 per circuit, a total of 8 per fusebox. Each:
$ 10.95
HCP24811 Aftermarket fusebox FUSEHOLDER CLIP TERMINAL, fits into stock factory fuseboxes, crimp-on, open-barrel style brass terminals fits all stock XJ-series fuseboxes that use glass fuses. Use 2 per circuit, a total of 8 per fusebox. Each:
$ 6.95
HCP23089 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the MAIN CIRCUIT and has the proper 14-gauge solid red wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). Each set:
$ 21.95
HCP23090 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the SIGNALS CIRCUIT and has the proper 18-gauge solid brown wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). Each set:
$ 21.95
HCP23091 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the IGNITION CIRCUIT and has the proper 18-gauge red with white tracer stripe wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). NOTE: some models used solid brown wires for the ignition circuit, in which case you can either use these (which we recommend doing), or, you can use the HCP23090 set above. Each set:
$ 21.95
HCP23092 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the HEADLIGHT CIRCUIT and has the proper 16-gauge red with yellow tracer stripe wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). NOTE: some models used solid brown wires for the headlight circuit, in which case you can either use these (which we recommend doing), or, you can use the HCP23090 set above. Each set:
$ 21.95
rf3) Aftermarket replacement GLASS AGC FUSES for use with the stock original fuseboxes or fuse holders.
NOTE: the following replacement fuses are slightly longer than the stock, original fuses (you still have those in there????!) but the additional length will not cause any problems with use.
HCP7144 Aftermarket glass tube 5-AMP AGC FUSE, each:
$ 0.45
HCP7144SET5 Aftermarket glass tube 5-AMP AGC FUSES, set of 5:
$ 1.95
HCP1276 Aftermarket glass tube 10-AMP AGC FUSE, each:
$ 0.45
HCP1276SET5 Aftermarket glass tube 10-AMP AGC FUSES, set of 5:
$ 1.95
HCP7145 Aftermarket glass tube 15-AMP AGC FUSE, each:
$ 0.45
HCP7145SET5 Aftermarket glass tube 15-AMP AGC FUSES, set of 5:
$ 1.95
HCP1275 Aftermarket glass tube 20-AMP AGC FUSE, each:
$ 0.45
HCP1275SET5 Aftermarket glass tube 20-AMP AGC FUSES, set of 5:
$ 1.95
HCP7143 Aftermarket glass tube 30-AMP AGC FUSE, each:
$ 0.45
HCP7143SET5 Aftermarket glass tube 30-AMP AGC FUSES, set of 5:
$ 1.95
The following fuses are the original “short” style fuses, and will certainly get your bike to the 11th level! Note that these fuses are current manufacturer (not 30 year-old fuses!):
HCP23094 Aftermarket glass tube 10-AMP ORIGINAL FUSE, each:
$ 1.95
HCP23095 Aftermarket glass tube 20-AMP ORIGINAL FUSE, each:
$ 1.95
HCP24653 Aftermarket glass tube 30-AMP ORIGINAL FUSE, each:
$ 1.95
Original Fusebox Hardware:
HCP23087 Aftermarket original-style fusebox plastic LID, black plastic snap-on lid fits and appears just like original.
$ 21.95
HCP23088 Aftermarket original-style fusebox plastic BASE, black plastic base accepts the original fuseholder clips just like the original.
$ 18.95
HCP787 OEM original fusebox rubber BOOT, covers the bottom edge of the stock fusebox and acts as an anti-vibration damper. Fits all original XJ-series fuseboxes (except XJ700 models), but was only used originally on XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 models. NOTE: you will need to use the HCP2520 screws, the HCP2519 collar, and the HCP306 washers with this boot.
$ 21.95
HCP314 OEM original fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Zinc-plated alloy steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 3.95
HCP5335 OEM fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Black alloy steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95
HCP915 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Zinc-plated alloy steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95
HCP316 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. 18-8 stainless steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95
HCP317 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. 18-8 stainless steel with a polished button head, hex-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.50
HCP318 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. 18-8 stainless steel with a smooth, polished socket head, hex-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.50
HCP320 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Black-oxide coated alloy steel with a ribbed socket head. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95
HCP2940 OEM original fusebox MOUNTING SCREW, black, phillips-drive, panhead, alloy steel screw. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 3.50
HCP2643 Aftermarket original fusebox MOUNTING SCREW, zinc-plated alloy steel, panhead, phillips drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.75
HCP302 Aftermarket original fusebox MOUNTING SCREW, 18-8 stainless steel, panhead, phillips-drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.50
HCP303 Aftermarket original fusebox MOUNTING SCREW, 18-8 stainless-steel, polished button head, hex-drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.95
HCP56 Aftermarket original fusebox MOUNTING SCREW, 18-8 stainless steel, smooth polished socket head, hex-drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.95
HCP58 Aftermarket original fusebox MOUNTING SCREW, black oxide-coated alloy steel, ribbed socket head, hex-drive For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.50
HCP383 OEM original fusebox-to-filter lid RETAINING SCREW, bright zinc-plated alloy steel, secures the fusebox to the filter lid on the airbox. Fits all XJ650 Maxim, Midnight Maxim, and 1982 XJ650 Turbo models, use 2 per fusebox, each:
$ 1.95
HCP21390 Aftermarket original fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Fits all XJ650 Maxim, Midnight Maxim, and 1982 XJ650 Turbo models, use 2 per fusebox. {b]NOTE[/b]: original screws may have had a blunt tip or a sharp, pointed tip. These replacement screws have a pointed tip. Each:
$ 1.25
HCP2520 OEM original fusebox-to-filter lid RETAINING SCREW, bright zinc-plated alloy steel, secures the fusebox to the filter lid on the airbox. Fits all XJ650RJ Seca, 1983 XJ650 Turbo, and all XJ750 models, use 2 per fusebox, each:
$ 2.95
HCP25893 Aftermarket original fusebox-to-filter lid RETAINING SCREW, bright 18/8 stainless steel, secures the fusebox to the filter lid on the airbox. Fits all XJ650RJ Seca, 1983 XJ650 Turbo, and all XJ750 models, use 2 per fusebox, each:
$ 1.95
HCP4168 OEM original fusebox-to-filter lid RETAINING SCREW, bright zinc-plated alloy steel. Secures the fusebox to the filter lid on the airbox. Fits all XJ900RK, RL, N/FN, and F models, use 2 per fusebox, each:
$ 2.95
HCP25892 Aftermarket original fusebox-to-filter lid RETAINING SCREW, bright 18-8 stainless steel. Secures the fusebox to the filter lid on the airbox. Fits all XJ900RK, RL, N/FN, and F models, use 2 per fusebox, each:
$ 1.95
HCP2519 OEM original fusebox-to-filter lid retaining screw COLLAR, hollow metal sleeve used with the HCP2520 screw above. Fits all XJ650RJ Seca, 1983 XJ650 Turbo, and all XJ750 models, use 2 per fusebox, each:
$ 1.95
HCP2173 OEM original fusebox-to-filter lid retaining screw FLAT WASHER, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, original bright finish, each:
$ 1.95
HCP6642 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, zinc-plated alloy steel with a natural finish, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 0.95
HCP6643 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, 18-8 stainless steel with a natural finish, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.25
HCP25756 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, 316 stainless steel with a natural finish, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95
HCP14285 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, black oxide-coated 18-8 stainless steel, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95
HCP14284 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, black oxide-coated hardened alloy steel, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95
HCP306 OEM original fusebox-to-filter lid retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 1.95
HCP914 Aftermarket fusebox-to-filter lid retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 1.00
HCP1353 Aftermarket fusebox-to-filter lid retaining screw FLAT WASHER, bright 18/8 stainless steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 1.00
HCP65 Aftermarket fusebox-to-filter lid retaining screw FLAT WASHER, black oxide-coated stainless steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 1.95
HCP55 OEM original fusebox mounting screw LOCK WASHER. For all FJ600 models, use 2 per fusebox, each:
$ 1.95
HCP913 Aftermarket original fusebox mounting screw LOCK WASHER. Zinc-plated alloy steel with a bright finish. For all FJ600 models, use 2 per fusebox, each:
$ 1.00
HCP57 Aftermarket original fusebox mounting screw LOCK WASHER. 18-8 stainless steel with a bright finish. For all FJ600 models, use 2 per fusebox, each:
$ 1.00
HCP59 Aftermarket original fusebox mounting screw LOCK WASHER. Black-oxide coated alloy steel with a dark finish. For all FJ600 models, use 2 per fusebox, each:
$ 1.00
HCP2940 OEM original accessory fuse terminal assembly MOUNTING SCREW, black, phillips-drive, panhead, alloy steel screw. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 3.50
HCP2643 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, zinc-plated alloy steel, panhead, phillips drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.75
HCP302 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, 18-8 stainless steel, panhead, phillips-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.50
HCP303 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, 18-8 stainless-steel, polished button head, hex-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95
HCP56 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, 18-8 stainless steel, smooth polished socket head, hex-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95
HCP58 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, black oxide-coated alloy steel, ribbed socket head, hex-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.50
HCP306 OEM original accessory fuse terminal assembly retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95
HCP914 Aftermarket original accessory fuse terminal assembly retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.00
HCP1353 Aftermarket original accessory fuse terminal assembly retaining screw FLAT WASHER, bright 18/8 stainless steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.00
HCP65 Aftermarket original accessory fuse terminal assembly retaining screw FLAT WASHER, black oxide-coated stainless steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95
HCP55 OEM original accessory fuse terminal assembly retaining screw mounting screw LOCK WASHER. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95
HCP913 Aftermarket original accessory fuse terminal assembly retaining screw LOCK WASHER. Zinc-plated alloy steel with a bright finish. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.00
HCP57 Aftermarket original accessory fuse terminal assembly retaining screw LOCK WASHER. 18-8 stainless steel with a bright finish. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.00
HCP59 Aftermarket original accessory fuse terminal assembly retaining screw LOCK WASHER. Black-oxide coated alloy steel with a dark finish. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.00
REPLACEMENT FUSEBOXES AND ACCESSORIES:
Upgrading your electrical system couldn't be simpler with one of our aftermarket style enclosed, waterproof fuse panels.....bringing your bike a long way up to 21st century standards of electrical wiring, and helping to prevent and eliminate annoying, frustrating, and down-right dangerous electrical issues that worn out stock fuseboxes suffer from.
So, if your fusebox (or the remains of it) look anything like this:
http://www.xjbikes.com/forums/index.php?threads/photo-of-new-fusebox-install.14200/#post-121673
or this:
http://xjbikes.com/forums/index.php?threads/fuse-panel-poll-yes-no-will-wont.9277/page-2#post-87015
then it's time to solve a number of problems and potential problems, all at once!
And here is the shocking video that everyone’s talking about, showing the entire install on an XJ650 Maxim model (other models, besides the XJ1100 and XS1100 models, are all basically the same procedure):
FITMENT: the stock Yamaha fusebox is very flat...less than an inch tall. These aftermarket fuseblocks are quite a bit taller, and therefore may present some challenges and the need for some creative engineering to place them properly. In some cases the small "document holder" under the seat may need to be removed. We offer the following tips:
XJ550 models (all): the stock fusebox lays on top of the "tool kit caddy", and the forward "arms" of this caddy hold both the TCI (on the right side) and the fusebox (on the left side). These aftermarket fuseboxes will not fit in the same place as the stock fusebox, as the increased height will cause interference with the bottom of the seat pan. The best fit can be obtained by carefully cutting away a portion of the left tool caddy "arm", so that the replacement fusebox can be attached to the top of the air filter housing. Careful positioning of the fusebox will allow you to remove a minimal amount of the tool caddy arm material, thus retaining the structural strength of that arm. The replacement fusebox should them be retaining to the top of the air filter box via two self-tapping screws, or proper sized bolts and nuts. Here is a good image of what it should look like when you're done:
http://xjbikes.com/forums/index.php?threads/14200
and
http://www.xjbikes.com/forums/threads/how-to-install-an-aftermarket-fuse-box.6350/page-2#post-523114
XJ650 all models (except Turbo) and all 1981-83 XJ750 models: the stock fusebox lays on top of the air cleaner box lid. The replacement fuseblock can go in the same area, but some care must be taken as to positioning to make sure that the bottom of the seat pan does not contact the top of clear cover of the fuseblock. You will have to slightly reposition the fuseblock from the original mounting holes to get everything to line up properly, and you may have to remove the small plastic "document holder" that snaps into the bottom of the seat pan to secure proper clearance. Most clearance issues on these models can be resolved with the use of our FITMENT TEMPLATE and SEAT SPACER KIT listed further below.
Here are the basic steps needed, shown on an XJ650 Maxim model; XJ650RJ Seca and XJ750 Maxim and Seca models are similar. Although this how-to uses a 4-circuit replace fusebox, our 6-circuit panel installs in the same manner:
http://xjbikes.com/forums/index.php?threads/6350
and
http://www.xjbikes.com/forums/threads/fuse-box-replacement.71502/
XJ650 Turbo models: the stock fusebox fits into a flat plastic holder "bar" that fits over the air cleaner box. This holder will no longer be used, and the replacement fusebox will need to be screwed directly to the top of the air cleaner box.
XJ700 and XJ750-X models: these bikes already use the push-in type fuses in a fuse panel (under the gauges) that already comes with ATC style fuses for the auxiliary circuits, and there is no need to upgrade that! Therefore these replacement 6-circuit fuseboxes are not needed on these bikes. However, they also use a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16766 listed further below.
XJ900 (and possibly XJ750RL) models: the stock fusebox sits in the "electrical components compartment" caddy under the seat. The replacement fusebox will fit in place of the original fusebox inside this caddy, but you will need to add the HCP12836 spacers to the frame tubes to space the seat pan up slightly (1/8") to prevent interference between the bottom of the seat pan and the top of the fusebox. Here's a great visual how-to:
http://xjbikes.com/forums/index.php?threads/3184
XJ1100 and XS1100 models: these models will require the installation of one of our adapter plates to properly install the enclosed fusebox on these models.
Also available are harness WIRING EXTENSION KITS that contain all the additional color-coded wiring leads, terminals, and connectors needed to make the installation of these aftermarket fuseboxes an even simpler fix!
All fuseboxes and component pieces are available individually, or as COMPLETE FUSEBOX UPGRADE KITS, which will give you everything you need to do it right, the first time!
q) We've developed a number of different COMPLETE FUSEBOX UPGRADE KITS to assist you in performing a professional replacement of the stock 4-circuit fusebox (or whatever other type of hacked wiring mess you inherited). Each kit contains the enclosed fusebox, bottom gasket, mounting screws, circuit ID decal, extension wires set, mounting templates (on some models), and seat spacers kit (on some models). In just a few hours time, you’ll be (electrically-speaking) riding in the modern world again.
All of our fusebox kits require no soldering and minimal electrical knowledge. With the use of our optional HCP17820 POWER JUMPER WIRE, you can easily add power to the two additional circuits in any of our 6-circuit fusebox kits, and have a conversion that looks professional and is done safely and properly.
NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.
XJ550 models:
https://www.facebook.com/VintageYam...383213023074/2004383213023074/?type=3&theater
HCP22570KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, installation template, circuit ID decal, and wiring extensions. Fits all XJ550 models.
$ 59.95
HCP22571KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, installation template, circuit ID decal, and wiring extensions. Fits all XJ550 models.
$ 64.95
XJ650 models:
HCP22572KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all XJ650 (except Turbo) models. NOTE: XJ650RJ Seca and XJ650 Euro models (with the hinged, “flip-up” style seat) may not require the use of the seat spacers included within this kit.
$ 64.95
HCP22573KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all XJ650 (except Turbo) models. NOTE: XJ650RJ Seca and XJ650 Euro models (with the hinged, “flip-up” style seat) may not require the use of the seat spacers included within this kit.
$ 69.95
HCP22574KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ650 Turbo models. NOTE: can be used on all other XJ650 models but does not include the seat spacers nor the installation template).
$ 59.95
HCP22575KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ650 Turbo models. NOTE: can be used on all other XJ650 models but does not include the seat spacers nor the installation template).
$ 64.95
XJ750 models:
HCP22576KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1982 XJ750 Maxim models.
$ 64.95
HCP22577KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1982 XJ750 Maxim models.
$ 69.95
HCP22578KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1983-84 XJ750 Maxim and Midnight Maxim models.
$ 64.95
HCP22579KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1983-84 XJ750 Maxim and Midnight Maxim models.
$ 69.95
HCP22580KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1981-83 XJ750 Seca and all XJ750 Euro models.
$ 62.95
HCP22581KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1981-83 XJ750 Seca and all XJ750 Euro models.
$ 67.95
XJ900 models:
HCP22582KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ900RK, RL, F, N, and FN models.
$ 59.95
HCP22583KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ900RK, RL, F, N, and FN models.
$ 64.95
XJ1100 models:
NOTE: XJ1100 owners actually have three fuse-holding devices to consider (and thus possibly upgrade):
1) the main circuit remote fuseholder, which is enclosed all by its lonesome as an appendage to the main wiring harness, and....
2) the 4-position "accessory circuits" black lastic fusebox, which mounts to the side of the battery box, and….
3) the 1-position "accessory circuit" terminal block, which mounts under the stock 4-position fusebox. Note that we do not have any “upgrade” option for this (rarely used) terminal block.
ALL of the above devices originally use the "old tech" type of AGC (“all glass” or “automotive glass”, depending on who you listen to……..) cylindrical glass fuses. AGC fuses are also sometimes referred to as SFE (“Society of Fuse Engineers”…..yes there is such an organization!) fuses.
We've developed a number of different kits to allow you to replace the stock 4-position accessory circuit fusebox (that's a must!) with a modern 6-circuit fusebox using the modern style ATO "blade" fuses. You then also have the option to choose between leaving the main fuseholder "as is" (remote from the main fusebox, in its own fuseholder), or, leaving it remote but replacing the original AGC fuse and holder with a modern blade-style ATO fuse and fuseholder.......or going fully modern and eliminating the remote main fuseholder entirely and bringing the main fuse circuit "inside" your new upgraded 6-position fusebox (note that this last choice will eliminate one potential "accessory circuit" from your new 6-circuit fusebox, since one of those "accessory circuits" is now populated by the main fuse circuit, which used to be remote from the fusebox).
Our recommendation: replace the stock remote main circuit fuseholder with a modern version (which uses the blade-style ATO fuse) and, of course, replace the original 4-position fusebox with our upgraded 6-circuit, enclosed, ATO fuseholder. This is what we refer to as “OPTION B” below. This arrangement brings your electrical system (as far as fuses are concerned) fully into the modern era.
Also note that the use of any of our replacement accessory-circuit fusebox kits will require you to modify or eliminate the accessory circuit terminal block unit, located on the bottom left "corner" of the stock fusebox mounting plate, as it makes for an incredibly tight fit for the routing of the circuit wires.
All of our fusebox kits require no soldering and minimal electrical knowledge. With the use of our optional HCP18421 mounting plate kit, you can ensure a quick and painless installation process, and have a professional conversion that both properly fits inside the frame side cover and looks factory-installed.
So here are your options; again, we suggest option B as the more useful and suitable for most owners:
OPTION A: If you want to keep the stock, remote MAIN CIRCUIT fuseholder as-is, and just upgrade the original accessory-circuits fusebox, then order either the HCP378BC or the HCP378LF 6-circuit fuesbox kits, the HCP16766 harness extension wires, and the HCP18421 installation kit:
Order either of these fuseboxes:
HCP378BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 20A), for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 29.95
HCP378LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with the optional “glow-when-blown” indicator style ATO push-in fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 34.95
and this:
HCP16766 Aftermarket 6-circuit fusebox HARNESS EXTENSION WIRES KIT. For all XJ1100 and XS1100 models.
$ 29.95
and this, which will make installation a breeze!:
HCP18421 Aftermarket fusebox MOUNTING PLATE KIT, contains a custom designed black steel mounting plate that allows quick and easy installation of the 6-circuit fusebox to your battery tray. Replaces the original stock fusebox mounting plate and retains and moves the turn signal flasher relay "out of harm's way", a necessity when using the larger aftermarket fusebox. Kit contains the mounting bracket, installation hardware, and illustrated instructions.
$ 49.95
NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.
Option “A” Complete Kits:
HCP26987-BC-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all XJ1100 models.
$ 84.95
HCP26987-LF-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all XJ1100 models.
$ 89.95
OPTION B: If you want to keep the MAIN fuseholder external from the accessory-circuits fusebox, but DO want to replace the stock glass-fuse main fuseholder with a later style "blade" fuse holder, AND upgrade the original accessory-circuits fusebox to a later style "blade" fusebox, then order the HCP16777 main fuseholder replacement kit, either the HCP378BC or the HCP378LF accessory-circuits fusebox kit, the HCP16766 harness extension wires kit, and the HCP18421 installation kit :
Order this:
HCP16777 Aftermarket MAIN FUSEHOLDER REPLACEMENT KIT, contains the weatherproof "blade" style HCP6833 main fuse holder with the white plastic connector shell that plugs into your main wiring harness (just like the original main fuseholder does).....no splicing, dicing, or harness chopping required! Includes 2 x 30A blade fuses (1 for use and 1 as a spare). For all XJ1100 and 1980-81 XS1100 models.
$ 29.95
and either of these fuseboxes:
HCP378BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 20A), for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 29.95
HCP378LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with the optional “glow-when-blown” indicator style ATO push-in fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 34.95
and this:
HCP16766 Aftermarket 6-circuit fusebox HARNESS EXTENSION WIRES KIT. For all XJ1100 and XS1100 models.
$ 29.95
and this, which will make installation a breeze!:
HCP18421 Aftermarket fusebox MOUNTING PLATE KIT, contains a custom designed black steel mounting plate that allows quick and easy installation of the 6-circuit fusebox to your battery tray. Replaces the original stock fusebox mounting plate and retains and moves the turn signal flasher relay "out of harm's way", a necessity when using the larger aftermarket fusebox. Kit contains the mounting bracket, installation hardware, and illustrated instructions.
$ 49.95
Option “B” Complete Kits:
HCP26988-BC-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all XJ1100 models.
$ 89.95
HCP26988-LF-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all XJ1100 models.
$ 94.95
OPTION C: If you want to bring the main fuse holder circuit "inside" of the upgraded 6-circuit enclosed fusebox, order either the HCP16769BC or the HCP16769LF fusebox kits below and the HCP16766 wiring harness extension wires kit....note that this eliminates the remote main circuit fuseholder entirely, and moves that circuit into one of the enclosed fusebox circuit positions:
Order either of these fusebox and main fuseholder kits:
HCP16769BC Aftermarket enclosed 6-circuit ENCLOSED 6-CIRCUIT FUSEBOX AND MAIN FUSEHOLDER ELIMINATOR KIT, allows for the elimination of the original remote "main circuit" fuseholder and the placement of the 30A main circuit path inside the new fusebox. The adapter wire has the white plastic connector shell that plugs into your main wiring harness just like the original main fuseholder does.....no splicing, dicing, or harness chopping required! Kit includes the enclosed fusebox, the main fuseholder eliminator harness, and a full complement of standard ATO blade type fuses (4 x 10A, 2 x 20A, and 2 x 30A). For all XJ1100 models.
$ 34.95
HCP16769LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX AND MAIN FUSEHOLDER ELIMINATOR KIT, allows for the elimination of the original remote "main circuit" fuseholder and the placement of the 30A main circuit path inside the new fusebox. The adapter wire has the white plastic connector shell that plugs into your main wiring harness just like the original main fuseholder does.....no splicing, dicing, or harness chopping required! Kit includes the enclosed fusebox, the main fuseholder eliminator harness, and a full complement of the optional ”glow-when-blown” indicator style ATO blade type fuses (4 x 10A, 2 x 20A, and 2 x 30A). For all XJ1100 models.
$ 37.95
and this:
HCP16766 Aftermarket 6-circuit fusebox HARNESS EXTENSION WIRES KIT. For all XJ1100 and XS1100 models.
$ 29.95
and this, which will make installation a breeze!:
HCP18421 Aftermarket fusebox MOUNTING PLATE KIT, contains a custom designed black steel mounting plate that allows quick and easy installation of the 6-circuit fusebox to your battery tray. Replaces the original stock fusebox mounting plate and retains and moves the turn signal flasher relay "out of harm's way", a necessity when using the larger aftermarket fusebox. Kit contains the mounting bracket, installation hardware, and illustrated instructions.
$ 49.95
Option “C” Complete Kits:
HCP26989-BC-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main fuseholder elimination/re-location harness. For all XJ1100 models.
$ 89.95
HCP26989-LF-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main fuseholder elimination/re-location harness. For all XJ1100 models.
$ 99.95
XS1100 models:
NOTE: on all XS1100 models, when replacing the stock 4-circuit fusebox, the turn signal flasher relay (flasher unit), which is located on the fusebox mounting plate, will cause interference with the the larger 6-circuit fusebox which is provided in our kits, and thus the flasher relay must be relocated. A plug-and-play extension harness and relay mounting bracket is included with our kits to make the relocation of the flasher relay a simple, painless, and professional-looking task (note that what we refer to as the “mounting plate” is the stamped metal plate which is attached to the right side of the battery tray structure, and holds the stock 4-circuit plastic fusebox, the 1-position accessory “terminal block”, the signal flasher relay, and the starter solenoid). However, the mounting “tab” for the flasher relay, which is stamped onto this mounting plate, will need to be removed or folded “out of the way”……..all of this is covered in the illustrated instructions included with the fusebox kit.
All kits include at least the following components: the enclosed, 6-circuit fusebox with a full supply of ATO blade fuses, a circuit ID decal, a fusebox mounting adapter plate, attaching hardware, a flasher relay re-location harness and mounting bracket, and full instructions.
All of our fusebox kits require no soldering and minimal electrical knowledge, and the illustrated instructions insure a quick and painless installation process (1-2 hours, depending on your skill level and mood), and will lead to a professional conversion that both properly fits inside the frame side cover and looks factory-installed.
1978-79 XS1100 models:
NOTE: 1978-79 XS100 owners actually have two fuse-holding devices:
1) the 4-position "accessory circuits" black plastic fusebox, which mounts to the side of the battery box, and which can be upgraded to a modern ATO 6-circuit fusebox, and…….
2) a 1-position "accessory circuit" terminal block, which mounts under the stock 4-position fusebox. Note that we do not have any “upgrade” option for this (rarely used) terminal block.
BOTH of the above devices originally use the "old tech" type of AGC (“all glass” or “automotive glass”, depending on who you listen to……..) cylindrical glass fuses. AGC fuses are also sometimes referred to as SFE (“Society of Fuse Engineers”…..yes there is such an organization!) fuses.
NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.
HCP26996BC Aftermarket FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this upgrade: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and the fusebox wiring kit. For all 1978-79 XS1100 models.
$ 94.95
HCP26996LF Aftermarket FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this upgrade: an enclosed 6-circuit fusebox with optional “glow-when-blown” indicator type ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and the fusebox wiring kit. For all 1978-79 XS1100 models.
$ 99.95
1980-81 XS1100 models:
NOTE: 1980-81 XS owners actually have three fuse-holding devices to consider (and thus possibly upgrade):
1) the main power circuit remote fuseholder, which is enclosed all by its lonesome as an appendage to the main wiring harness, and....
2) the 4-position "accessory circuits" black plastic fusebox, which mounts to the side of the battery box, and which can be upgraded to a modern blade-style ATO 6-circuit fusebox, and…….
3) a 1-position "accessory circuit" terminal block, which mounts under the stock 4-position fusebox. Note that we do not have any “upgrade” option for this (rarely used) terminal block.
ALL of the above devices originally use the "old tech" type of AGC (“all glass” or “automotive glass”, depending on who you listen to……..) cylindrical glass fuses. AGC fuses are also sometimes referred to as SFE (“Society of Fuse Engineers”…..yes there is such an organization!) fuses.
We've developed a number of different kits to allow you to replace the stock 4-position accessory circuit fusebox (that's a must!) with a modern 6-circuit fusebox using the modern style ATO "blade" fuses. You then also have the option to choose between leaving the main fuseholder "as is" (remote from the main fusebox, in its own fuseholder), or, leaving it remote but replacing the the main fuseholder AGC fuse and holder with a modern blade-style ATO fuse and fuseholder.......or going fully modern and eliminating the remote main fuseholder entirely, and bringing the main fuse circuit "inside" your new upgraded 6-position fusebox (note that this last choice will eliminate one potential "accessory circuit" from your new 6-circuit fusebox, since one of those "accessory circuits" is now populated by the main fuse circuit, which used to be remote from the fusebox).
Our recommendation: replace the stock remote main circuit fuseholder with a modern version (which uses the blade-style ATO fuse) and, of course, replace the original 4-position fusebox with our upgraded 6-circuit, enclosed, ATO fuseholder. This is what we refer to as “OPTION B” below. This arrangement brings your electrical system (as far as fuses are concerned) fully into the modern era.
NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.
OPTION A KITS: If you want to keep the stock, remote MAIN CIRCUIT fuseholder as-is, and just upgrade the original accessory-circuits fusebox, then order either of the fusebox kits below.
HCP26997BC-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all 1980-81 XS1100 models.
$ 84.95
HCP26997LF-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with the optional “glow-when-blown” ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all 1980-81 XS1100 models.
$ 89.95
OPTION B KITS: If you want to keep the MAIN fuseholder external (outside) from the accessory-circuits fusebox, but DO want to replace the stock glass-fuse main fuseholder with a later style "blade" fuse holder, AND upgrade the original accessory-circuits fusebox to a later style "blade" fusebox, then order either of the fusebox kits below.
HCP26998BC-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all 1980-81 XS1100 models.
$ 89.95
HCP26998LF-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all 1980-81 XS1100 models.
$ 94.95
OPTION C KITS: If you want to bring the stock external MAIN fuse holder circuit "inside" of the upgraded 6-circuit enclosed fusebox, order either of the fusebox kits below……note that this eliminates the remote main circuit fuseholder entirely, and moves that main fuse circuit into one of the enclosed fusebox circuit positions:
HCP26999BC-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main circuit fuseholder elimination/re-location harness. For all 1980-81 XS1100 models.
$ 89.95
HCP26999LF-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main circuit fuseholder elimination/re-location harness. For all 1980-81 XS1100 models.
$ 94.95
Individual Fusebox Components:
u177) Aftermarket 6-CIRCUIT ENCLOSED FUSEBOX. This small, weatherproof fusebox is the most popular replacement for the stock glass-tube fusebox and use "modern" type ATO push-in blade style fuses. Includes 6 ATO standard fuses, 2 x 20A or 2 x 30A (depending on your model), and 4 x 10A fuses. Two more circuits than a stock fusebox allows you to add extra circuits for heated grips, cigarette lighter, headlight relays, etc. Size: 4" long x 1-1/8" wide (not including spade terminals) x 1-1/2" tall (including the clear, see-through cover). Note that this is a "side-terminal" design...the male wire terminal spades point outwards (away) from the sides of the fusebox. Rated for 30 amps maximum current per circuit, and 70 amps maximum current draw for the entire box.
NOTE: fuseboxes do not come with mounting screws; you may re-use your original or order new replacements listed further below. Mounting screw locations will differ from original, and it will be necessary to re-locate at least one (and probably both) to get a correct fit. The HCP21390 mounting screw is the shortest, self-tapping screw available, and is the best length to use on all models. The original mounting screws on XJ550 models is slightly larger in diameter than the mounting holes in these replacement fuseboxes, and thus the hole in the fusebox base will need to be enlarged slightly on those models if you re-use the original mounting screws.
HCP21390 Aftermarket original fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. For use with any of our aftermarket fuseboxes below on all XJ550 - XJ900 models. Use 2 per fusebox, each:
$ 1.25
Individual Fusebox Components:
HCP378NOFUSE Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX, fusebox base and lid only; no fuses included, can be used on all models except all XJ700 and XJ750-X (water-cooled) bikes.
$ 24.95
HCP378BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 20A), for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 29.95
HCP378LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with the optional “glow-when-blown” indicator style ATO push-in fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 34.95
HCP7153BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK, RL, N/FN, and F models.
$ 29.95
HCP7153LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of glow-when-blown indicator style ATO push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK, RL, N/FN, and F models.
$ 34.95
HCP10488BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (1 x 30A, 1 x 20A, and 4 x 10A), for all 1984-85 FJ600, 1984 XJ750RL Seca, and all XS1100 models.
$ 29.95
HCP10488LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of glow-when-blown indicator style ATO push-in style fuses (1 x 30A, 1 x 20A, and 4 x 10A), for all 1984-85 FJ600, 1984 XJ750RL Seca, and all XS1100 models..
$ 34.95
u73) Aftermarket fusebox FITMENT TEMPLATE for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. These templates show you the proper method of fitting these fuseboxes into the cramped area of the original boxes, with proper placements and alignments for a fool-proof, no-guesswork fit. XJ650 and XJ750 models may also require a separate SEAT SPACER KIT (even with "perfect" fit) in order to prevent rubbing of the bottom of the seat pan against the top of the fusebox lid.
HCP12833 Aftermarket 6-circuit fusebox FITMENT TEMPLATE, for use with all XJ550 models.
$ 9.95
HCP12834 Aftermarket 6-circuit fusebox FITMENT TEMPLATE, for use with all XJ650 (except Turbo) models.
$ 9.95
HCP12835 Aftermarket 6-circuit fusebox FITMENT TEMPLATE, for use with all 1981-83 XJ750 models.
$ 9.95
HCP12836 Aftermarket 6-circuit fusebox SEAT SPACER KIT, for use with all XJ650 Maxim and Midnight Maxim models, all 1981-83 XJ750 models, and XJ900 models. Contains a set of 4 rubber frame tube "spacers" and a spacer mounting location template. NOTE: depending on your weight, airbox adjustment position, and the condition of your seat pan (they tend to "sag" over time), the use of these spacers may or may not be required on individual bikes.
$ 9.95
nnn) Aftermarket CIRCUIT ID DECAL for the above 6-circuit fuseboxes. Printed on a clear adhesive backed long-life decal material, this decal specifies (in white print) the circuit "name" (MAIN, HEAD, TURN, IGN.), the fuse amp rating of each circuit, and the wire lead color code (BLU, RED, R/Y, BRN, R/W) so you can have the same circuit ID info on your replacement fusebox as on your original. Applies to the outside of the clear fusebox cover. The two empty circuit positions are titled "SPARE".
HCP393 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 20A main fuse and 10A headlight, ignition, and signal circuits, for all XJ550, all XJ650, and 1983 XJ750 Maxim and XJ750 Midnight Maxim models.
$ 12.95
HCP20241 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse, 20A headlight circuit, and 10A ignition and signal circuits, for all 1984-85 FJ600 models.
$ 12.95
HCP7152 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse and 10A headlight, ignition, and signal circuits, for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK, RL, N/FN, and F models.
$ 12.95
HCP26951 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse, 10A headlight circuit, 20A signal circuit, and 10A ignition circuit. For all 1978-79 XS1100 models.
$ 12.95
HCP13475 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 10A taillight fuse, 10A headlight circuit, 20A signal circuit, and 10A ignition circuit. For all XJ1100 and 1980-81 XS1100 models in the stock configuration (with the main fuse circuit remaining external to the fusebox).
$ 12.95
HCP26952 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse, 10A taillight fuse, 10A headlight circuit, 20A signal circuit, and 10A ignition circuit. For all XJ1100 and all 1980-81 XS1100 models when the main fuse circuit is brought inside the fusebox. Note that this is not the configuration for these models when maintaining the stock fusebox orientation; for the original configuration use decal HCP13475.
$ 12.95
u7) Aftermarket fusebox BOTTOM GASKET for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. These fuseboxes have an "open" bottom, which would allow moisture and, eventually, corrosion to get into this otherwise sealed fuseblock. This die cut 1/16" thick rubber gasket has pre-punched mounting holes.
HCP382 Aftermarket 6-circuit fusebox BOTTOM GASKET:
$ 8.95
u71) Aftermarket fusebox WIRING EXTENSION KITS for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. Because the above replacement fuseboxes normally have to be slightly repositioned from the stock fusebox location (to insure adequate seat pan clearance), and due to the fact that the original lead wires coming off the main engine harness are crimped onto the original fusebox terminals (and will have to be cut a bit short during removal), these wiring harness extension kits are highly recommended to greatly simplify the installation of your new fusebox. The extra length of these wires gives you the option to locate your new fusebox in a variety of more suitable positions.
Each wiring kit comes complete with 12" lengths of the proper color-coded wire leads for each of the four original circuits with insulated female spade terminals (already attached to the fusebox end of each wire) and a full set of the proper size butt connectors for attaching the wire leads to the original main harness wires. The additional wire length allows you to place the fusebox virtually anywhere that you need (or want to), eliminating the frustrating task of cobbling together the additional extra wire leads to install the replacement fusebox.
HCP8553 Aftermarket WIRING EXTENSION KIT, contains all of the correct gauge and solid- and tracer-striped color wires to allow for the easy installation of any of our aftermarket 6-circuit enclosed fuseboxes in the following bikes: all XJ550, XJ650, XJ750 Maxim and Midnight Maxim, 1984 XJ750RL Seca, and XJ900RK, RL, N/FN, and F models.
$ 29.95
HCP8554 Aftermarket WIRING EXTENSION KIT, contains all of the correct gauge and solid- and tracer-striped color wires to allow for the easy installation of any of our aftermarket 6-circuit enclosed fuseboxes in the following bikes: all 1981-83 XJ750 Seca, all XJ750 Euro, and 1978-79 XS1100 models.
$ 29.95
HCP16766 Aftermarket WIRING EXTENSION KIT, contains all of the correct gauge and solid- and tracer-striped color wires to allow for the easy installation of any of our aftermarket 6-circuit enclosed fuseboxes in the following bikes: all XJ1100 and 1980-81 XS1100 models.
$ 29.95
HCP27207 Aftermarket fusebox wire OPTIONAL INSTALLATION HARDWARE KIT. This kit contains a full set of un-insulated butt connectors and heat-shrink tubing (as well as cable ties and harness clips) that is needed when hooking up the fusebox wires to the main harness wires. NOTE: all of our complete fusebox kits or fusebox wiring harness kits already contain a set of insulated wire connectors; this kit contains (basically) the same type of connectors, but they are the thinner, less-noticable un-insulated connectors, and appropriate lengths of heat-shrink tubing (to cover the un-insulated connectors after they are installed). Not an absolutely necessary kit to have ---- as noted, all of our complete fusebox kits and wiring harness kits already come with the bigger, bulkier insulated butt connectors --- but many people prefer these thinner, more streamlined connectors to create a more professional-looking and weatherproof method of attaching the fusebox wires to the main harness wires when using our aftermarket enclosed ATO fusebox kits. . Can be used with all of our aftermarket enclosed fusebox kits.
$ 9.95
HCP17820 Aftermarket fusebox POWER JUMPER WIRE, allows you to power up the two additional circuits in any of our enclosed 6-circuit fusebox kits. This jumper wire replaces the thick (14 gauge) tan wire in our HCP8553 or HCP8554 wire harness extension wire kits, and jumpers the power feed into the fusebox into the two additional "SPARE" circuit terminals. Plug-and-play operation, creates a neat, orderly, and safe power feed system for utilizing the two additional circuits. Includes a pair of 16-gauge female spade wire-end terminals for hooking up the accessory circuits to the outbound side of the fusebox (but no wire is included) NOTE: the wires used for the spare circuit power feeds in this power jumper wire are: HCP9547 (pink with black tracer stripe) for one circuit, and HCP9548 (purple with white tracer stripe) for the other circuit. Both are 16-gauge GXL wire, and can be used for circuits requiring up to 15 amps of current. Additional lengths of each of these wire can be ordered below, for the "outbound" side of your fusebox, so that you can color-code your accessory circuit wire runs with the same color wires.......a very professional touch.
$ 19.95
Accessory Color Wire:
Sometimes, you'll want to add electrical accessory circuits to you bike.....a cigarette lighter, heated grips, perhaps a power port for a GPS unit, etc......and in such situations, it's best to run a separate circuit, with its own unique color-coded wiring, in order to keep things neat and orderly, electrically-speaking. We offer the following unique colors (not used anywhere else on your bike) to help you safely and accurately identify any new circuits that you add.
HCP9547 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge. Sold per foot:
$ 2.95
HCP9547SET5 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 5-foot length:
$ 12.95
HCP9547SET10 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 10-foot length:
$ 19.95
HCP9548 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge. Sold per foot:
$ 2.95
HCP9548SET5 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 5-foot length:
$ 12.95
HCP9548SET10 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 10-foot length:
$ 19.95
Electrical System Chemicals:
NOTE: it’s important to understand the difference between the two types of greases used with electrical connectors. Di-electric grease acts as an electrical insulator: it does not allow current to flow through it easily, and is basically used to “waterproof” a connector assembly. Although it is an insulator, the act of engaging two electrical connectors together (i.e. pushing a male connector into a female connector) will push away the grease on the metal-to-metal contact portion of the terminals, so those remain electrically conductive (good) while also insulating all the other surfaces against moisture and oxygen intrusion (very good). This insulating property of di-electric grease makes it great for use in connector shells, etc. as terminal corrosion is one of the greatest contributors to electrical system problems in vehicles (especially older ones)……this is why most modern vehicles use “sealed” connector shells (the most popular is the Delphi Automotive brand called “weather pack” or “weatherpak”) to keep oxygen and moisture away from the metal terminals. Although you can retrofit these style connectors to older harnesses, it takes a LOT of time, money, and effort to do so.
Now, contrast the insulating properties of di-electric grease to the electrically conductive properties of Conductive Grease, which, as its name implies, the grease itself (which contains many fine carbon particles) conducts electricity. Of course, being a “grease”, it too will also protect and insulate a terminal coated with it from moisture, corrosion, etc…..same as di-electric grease. But…it’s conductive, and if the terminal it coats is electrically “hot”, so is the grease (i.e. touching the grease alone will shock you!).
So a conductive grease is great when you need protection plus current flow……ideal for frame (or battery) grounds to the frame, etc. You could---if you are totally anally-retentive---coat (for instance) a battery post internally with conductive grease, and then cover all of that with di-electric grease.
So, think of these grease as two different electrical system “tools”, and use accordingly.
et2) Aftermarket electrical connector DI-ELECTRIC GREASE coats, insulates, and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Smear some of this goo on each and every one of your electrical connectors (after you've cleaned them with some sandpaper or terminal cleaner) and you'll be doing yourself a big favor!
HCP14059 Aftermarket packet of DI-ELECTRIC GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc.
$ 1.95
HCP7528 Aftermarket tube of DI-ELECTRIC GREASE, big 3-ounce squeeze tube.
$ 14.95
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP20940 Aftermarket tube of DI-ELECTRIC GREASE, 3.3-ounce aerosol can of marine grade grease, with adjustable nozzle size to tailor the grease output bead size to minimize slop and waste and making application much easier. 1-2 cans will do all connectors on an entire bike harness.
$ 17.95
et14) Aftermarket electrical connector CONDUCTIVE GREASE coats and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Unlike the di-electric grease listed above, which is an insulator (non-conductive), this carbon-based grease is electrically conductive and has multiple applications (such as battery terminal posts (internally), frame grounds, etc.).
HCP27923 Aftermarket packet of CONDUCTIVE GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc. Even tiny amounts (that you can barely see) will create minimal electrical resistance, so be careful with this stuff around capacitors and such. It gets everywhere, will stain your hands and clothing and take three days to wash off, and smells like some of the worst goop you've ever smelled. Use a toothpick for application. Don't eat it. Wear gloves. 2-gram pouch goes a long way.
$ 3.95
cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn’t “shed” particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2” wide x 1-foot long strip, enough for polishing many a commutator or contact.
HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12” x 2”. Each:
$ 3.95
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP9762 Aftermarket miracle-goo black LIQUID ELECTRICAL TAPE is easier to use than traditional tape products, especially in close-in locations. Great for sealing crimped wire terminal ends to the wire and serves as a good alternative or supplement to shrink tubing. Just brush it on and let it dry! Comes in a 4-ounces brush-top can.
$ 8.95
HCP10508 Aftermarket electrical CONTACT CLEANER is a good general purpose cleaner and de-greaser. Will not harm plastic terminal connector blocks. Fast drying and leaves no residue. Comes in a 16-ounce aerosol can.
$ 9.95
HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 4.95
HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 10.95
r) Replacement 8-CIRCUIT ENCLOSED FUSEBOX. This small, weatherproof ATC (mini push-in blade style fuse) fusebox is the most popular replacement for the stock glass-tube fusebox and is the type that many owners use. Same as the HCP378 fusebox above, but with two extra slots for a total of 8 circuits, in case you need to add even more circuits. Includes a total of eight ATC push-in style fuses, 2 x 20A and 6 x 10A.
Size: 4-1/2" long x 1-1/8" wide (not including the wire terminal spades) x 1-5/8" tall (including the clear cover). Note that this is a "bottom-terminal" design...the male spades point down towards the base of the fusebox, rather than out the sides. . THIS FEATURE CAN MAKE THE INSTALLATION OF THIS FUSEBOX TRICKY ON THESE BIKES, and the additional height of this box will cause interference problems between the fusebox cover and the bottom of the seat pan on stock bikes.
HCP379BC Aftermarket FUSEBOX, 8-circuit with a full set of standard style ATC push-in style fuses (6 x 10A, and 2 x 20A).
$ 16.95
HCP379LF Aftermarket FUSEBOX, 8-circuit with a full set of "glow-when-blown" indicator style ATC push-in style fuses (6 x 10A, and 2 x 20A).
$ 19.95
In-Line Fuseholders:
rf1) Aftermarket replacement individual INLINE FUSE HOLDER, heavy-duty waterproof style features a snap-close cap and accepts the standard or "glow-when-blown" type ATC/ATO push-in style fuses.
NOTE: on all XJ models except XJ700, 1982 XJ750 Maxim, XJ750 Seca, and XJ1100 models, the original fusebox uses a 20A fuse for the main circuit, and 10A fuses for the headlight, turn signals, and ignition circuits. Upgrading to a larger capacity fuse HOLDER poses no problems or issues, but [/b]NEVER[/b] use a larger fuse than the original rated capacity of a circuit (regardless of what "size" fuseholder you use on the circuit).
XJ700 models used a fuse panel (under the gauges) that already comes with ATC style fuses for the auxiliary circuits, and there is no need to upgrade that! However, the XJ700 models use a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16777 listed below.
XJ1100 models used a standard style glass-fuses panel along with a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16777 listed below.
HCP7122 Aftermarket standard IN-LINE FUSE HOLDER, solid colored thermoplastic housing, 6" long, 16-gauge wire leads, 10A capacity, each:
$ 3.95
HCP6833 Aftermarket standard IN-LINE FUSE HOLDER, solid colored thermoplastic housing, 6" long, 12-gauge wire leads, 30A capacity, each:
$ 4.95
HCP6833SET4 Aftermarket standard IN-LINE FUSE HOLDERS, solid colored thermoplastic housing, set of 4:
$ 17.95
HCP16777 Aftermarket MAIN FUSEHOLDER REPLACEMENT KIT, contains the weatherproof "blade" style HCP6833 main fuse holder with the white plastic connector shell that plugs into your main wiring harness (just like the original main fuseholder does).....no splicing, dicing, or harness chopping required! Includes 2 x 30A blade fuses (1 for use and 1 as a spare). Fits all XJ700, XJ750-X, XJ1100, and 1980-81 XS1100 models.
$ 16.95
HCP6834 Aftermarket see-through IN-LINE FUSE HOLDER, designed to be used with the "glow-when-blown" fuses, 4" long, 12-gauge wire leads, 20A capacity, each:
$ 7.95
HCP6834SET4 Aftermarket see-through IN-LINE FUSE HOLDERS, set of 4:
$ 29.95
Replacement Fuses:
rf2) Aftermarket replacement ATC/ATO FUSES, for use with the above 6- or 8-circuit replacement fuseboxes or the in-line fuseholders. Both the standard style and "Glow-When-Blown" fuses are high quality products that meet or exceed current vehicle manufacturer specifications.
HCP7149 Aftermarket standard type 5-AMP ATC/ATO FUSE, orange, push-in style, each:
$ 0.95
HCP7149SET5 Aftermarket standard type 5-AMP ATC/ATO FUSES, orange, push-in style, set of 5:
$ 3.95
HCP381 Aftermarket standard type 10-AMP ATC/ATO FUSE, red, push-in style, each:
$ 0.95
HCP381SET5 Aftermarket standard type 10-AMP ATC/ATO FUSES, red, push-in style, set of 5:
$ 3.95
HCP7150 Aftermarket standard type 15-AMP ATC/ATO FUSE, blue, push-in style, each:
$ 0.95
HCP7150SET5 Aftermarket standard type 15-AMP ATC/ATO FUSES, blue, push-in style, set of 5:
$ 3.95
HCP380 Aftermarket standard type 20-AMP ATC/ATO FUSE, yellow, push-in style, each:
$ 0.95
HCP380SET5 Aftermarket standard type 20-AMP ATC/ATO FUSES, yellow, push-in style, set of 5:
$ 3.95
HCP7151 Aftermarket standard type 30-AMP ATC/ATO FUSE, green, push-in style, each:
$ 0.95
HCP7151SET5 Aftermarket standard type 30-AMP ATC/ATO FUSES, green, set of 5:
$ 3.95
The following are innovative "Glow-When Blown" ATC/ATO mini-fuses that incorporate a small, bright indicator light that activates when the fuse blows, thus making the identification of a disrupted circuit easy to spot:
HCP7147 Aftermarket "GLOW-WHEN-BLOWN" 5-AMP ATC/ATO FUSE, tan, push-in style, each:
$ 2.95
HCP7147SET5 Aftermarket "GLOW-WHEN-BLOWN" 5-AMP ATC/ATO FUSES, tan, push-in style, set of 5:
$ 12.95
HCP6832 Aftermarket "GLOW-WHEN-BLOWN" 10-AMP ATC/ATO FUSE, red, push-in style, each:
$ 2.95
HCP6832SET5 Aftermarket "GLOW-WHEN-BLOWN" 10-AMP ATC/ATO FUSES, red, push-in style, set of 5:
$ 12.95
HCP7148 Aftermarket "GLOW-WHEN-BLOWN" 15-AMP ATC/ATO FUSE, blue, push-in style, each:
$ 2.95
HCP7148SET5 Aftermarket "GLOW-WHEN-BLOWN" 15-AMP ATC/ATO FUSES, blue, push-in style, set of 5:
$ 12.95
HCP6831 Aftermarket "GLOW-WHEN-BLOWN" 20-AMP ATC/ATO FUSE, yellow, push-in style, each:
$ 2.95
HCP6831SET5 Aftermarket "GLOW-WHEN-BLOWN" 20-AMP ATC/ATO FUSES, yellow, push-in style, set of 5:
$ 12.95
HCP7146 Aftermarket "GLOW-WHEN-BLOWN" 30-AMP ATC/ATO FUSE, green, push-in style, each:
$ 2.95
HCP7146SET5 Aftermarket "GLOW-WHEN-BLOWN" 30-AMP ATC/ATO FUSES, green, push-in style, set of 5:
$ 12.95