Hello All

Hello all, just joined up. Hope to get my 1980 XJ650 Maxim on the road again. I'm searching the forums for some answers to some electrical problems. Expect some questions soon. :?

 

Welcome aboard Chuck! You've definitely come to the right place.

mikeg

 

let me answer your first question even though you havent asked it yet.

yep change the stock fuse block to a modern blade style fuse.

welcome. also where you from? be sure to add that under your avatar.

 

Welcome Chuck and Answers-R-Us. At least as long as Rick is here.

 

And here they are, Fuseboxes-R-Us!:

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 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.

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.

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 the 30A main circuit fuse panel 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 fuses.

XJ1100 models also used two separate fuse panels: one that contained the four secondary circuits, including one 20A fuse, and three 10A fuses, and which is located behind the right side panel; the 30A main circuit fuse panel was located under the seat.

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. 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.

XJ650 all models (except Turbo) and all 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.

XJ650 Turbo models: not yet verified.

XJ700 models: these bikes already use the push-in type fuses in a fusepanel located under the dash warning lights by the gauge cluster. Therefore these replacement 6-circuit fuseboxes are not needed on these bikes. However, the main 30-amp glass fuses and holder could benefit from the addition of the ATC in-line fuse holders.

XJ900 models: not yet verified.

XJ1100 models: not yet verified.


Also available are harness WIRING EXTENSION KITS that contain all the additional color-coded wiring leads, terminals, and connectors needed to make the installationof these aftermarket fuseboxes an even simpler fix!



q) Replacement 6-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. Includes 6 ATC 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.


HCP378BC Replacement FUSEBOX, 6-circuit design, comes with a full set of standard style ATC 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.
$ 13.00

HCP378LF Replacement FUSEBOX, 6-circuit with a full set of glow-when-blown indicator style ATC push-in style fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models.
$ 16.00


HCP7153BC Replacement FUSEBOX, 6-circuit design, comes with a full set of standard style ATC push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK models.
$ 13.00

HCP7153LF Replacement FUSEBOX, 6-circuit with a full set of glow-when-blown indicator style ATC push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK models.
$ 16.00


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 (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 Replacement HCP378xx fusebox 6-circuit I.D. Decal, with 20A main fuse labeling, for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models.
$ 4.00

HCP7152 Replacement HCP7153xx fusebox 6-circuit I.D. Decal, with 30A main fuse labeling, for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK models.
$ 4.00



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 Replacement 6-circuit fusebox Bottom Gasket:
$ 3.50



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.

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 the HCP378xx or HCP7153xxx fusebox in the following bikes: all XJ550, XJ650, XJ750 Maxim and Midnight Maxim, and XJ900RK models.
$ 12.95

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 the HCP378xx or HCP7153xxx fusebox in the following bikes: all XJ750 Seca and XJ1100 models.
$ 13.95

 

Welcome, Chuck!

Oh goody! More electrical problems.

Bring 'em on, Chuck. Me likes a challenge.

 

Thanks for all tips. I have replaced my stock fuse box with a similar fuse block from Radio Shack, although I think I should have gone with the blade fuses instead of the old barrel style. Nevertheless I am getting good continuity on these and will probably replace them with the blades soon. My next goal is to go through the starter circuit trobleshooter by Gamuru. The only question I have is does the 1980 XJ650 Maxim have a kickstand shut off switch because I can't find one on there? Thanks again

 

Nope, no sidestand safety switch on the 1980-81 XJ650 models!

 

How's that for service, Chuck? Welcome aboard, and enjoy the new toy.

(Check your pm box, Chacal.)