Fuse Panel... Where to buy one?

I have a 81 650 Maxim and i read that it is a good idea to replace the fuse panel on them.

Does anyone know a good place to buy a panel?

What other things should I work on right off the bat that may save me future hassles?

Thanks, 8)

 

CHACAL is the local parts guru - he has everything (almost) - I used a block from autozone but he ones others have used are bit nicer than mine

 

This is the one that I used.

 

What I did was went to Autozone and purchased inline spade fuse holders and soldered them onto the existing wires. I tucked them under the seat out site and haven't had a problem yet! I think it cost about $15.00 total with fuses and an hour in the garage.

 

Mine was that way but with butt splices - my first ride and a wire came out! I considered soldering them in but I got my fuse block for < $3 so I soldered it in.

 

Never butt-joint, ALWAYS solder.

 

Which bikes need replacement?

I'm a new-to-me owner of an XJ700 Maxim (1985) and I'm in the process of familiarizing myself with the bike and this site. I'm coming across posts every now and again regarding changing out your fuse box. What is the purpose of this? Are the old fuse-boxes prone to failure? Any particular model years that need this mod?

Thanks

 

Yup PO was responsible for the Butt splices.

I never use them for that very reason.

 

Re: Which bikes need replacement?

Congrats and welcome. They break; short;open up and all kinds of nasty things. they are over 25 years old after all. Replace it with a blade type box.

 

Thanks Bill. I'll add this to the list and git 'er done.

 

Here you go!:


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 seondary 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 seondary 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 moutning 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.






q) Replacement FUSEBOX, enclosed, weatherproof 6-circuit ATC (mini push-in blade style) fusebox....the style that everyone recommends using. Includes 6 ATC standard fuses, 2 x 20A or 2 x 30A (depending on your model), and 4 x 10A. 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.


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) Circuit ID Decal for the above 6-circuit HCP378BC fusebox. 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 HCP378BC clear fusebox cover. The two empty circuit positions are titled "SPARE".

HCP393 Replacement HCP378xx fusebox 6-circuit I.D. Decal, with 20A main fuse labelling, 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) Bottom Gasket for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. The fusebox has an "open" bottom, which would allow moisture and, eventually, corrosion to get into this otherwise sealed fuseblock. This die cut 1/16" rubber gasket has pre-punched mounting holes.

HCP382 Replacement 6-circuit fusebox Bottom Gasket:
$ 3.50




r) Replacement FUSEBOX, enclosed, weatherproof 8-circuit ATC (mini push-in blade style) fusebox. 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, rayjer than out the sides. THIS FEATURE CAN MAKE THE INSTALLATION OF THIS FUSEBOX TRICKY ON THESE BIKES, and the additional height of this box can cause interference problems between the fusebox cover and the bottom of the seat pan on some models.

HCP379BC Replacement FUSEBOX, 8-circuit with a full set of standard style ATC push-in style fuses (6 x 10A, and 2 x 20A).
$ 15.00

HCP379LF Replacement 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).
$ 18.00



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, 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 NEVER use a larger fuse than the original rated capacity of a circuit (regardless of what "size" fuseholder you use on the circuit).

HCP7122 aftermarket standard inline FUSE HOLDER, solid colored thermoplastic housing, 6" long, 16-gauge wire leads, 10A capacity, each:
$ 2.50


HCP6833 aftermarket standard inline FUSE HOLDER, solid colored thermoplastic housing, 6" long, 12-gauge wire leads, 30A capacity, each:
$ 2.75

HCP6833SET4 aftermarket standard inline FUSE HOLDER, solid colored thermoplastic housing, set of 4:
$ 9.00


HCP6834 aftermarket see-through inline FUSE HOLDER, designed to be used with the "glow-when-blown" fuses, 4" long, 12-gauge wire leads, 20A capacity, each:
$ 7.50

HCP6834SET4 aftermarket see-through inline FUSE HOLDER, set of 4:
$ 27.00



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 5A ATC/ATO (orange) push-in FUSE, each:
$ 0.75

HCP7149SET5 aftermarket standard type 5A ATC/ATO (orange) push-in FUSES, set of 5:
$ 2.50


HCP381 aftermarket standard type 10A ATC/ATO (red) push-in FUSE, each:
$ 0.75

HCP381SET5 aftermarket standard type 10A ATC/ATO (red) push-in FUSES, set of 5:
$ 2.50


HCP7150 aftermarket standard type 15A ATC/ATO (blue) push-in FUSE, each:
$ 0.75

HCP7150SET5 aftermarket standard type 15A ATC/ATO (blue) push-in FUSES, set of 5:
$ 2.50


HCP380 aftermarket standard type 20A ATC/ATO (yellow) push-in FUSE, each:
$ 0.75

HCP380SET5 aftermarket standard type 20A ATC/ATO (yellow) push-in FUSES, set of 5:
$ 2.50


HCP7151 aftermarket standard type 30A ATC/ATO (green) push-in FUSE, each:
$ 0.75

HCP7151SET5 aftermarket standard type 30A ATC/ATO (green) push-in FUSES, set of 5:
$ 2.50


The following are innovative "Glow-When Blown" ATC/ATO mini-fuses that incoporate 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" type 5A ATC/ATO (tan) push-in FUSE, each:
$ 1.25

HCP7147SET5 aftermarket "glow-when-blown" type 5A ATC/ATO (tan) push-in FUSE, set of 5:
$ 4.50


HCP6832 aftermarket "glow-when-blown" type 10A ATC/ATO (red) push-in FUSE, each:
$ 1.25

HCP6832SET5 aftermarket "glow-when-blown" type 10A ATC/ATO (red) style push-in FUSE, set of 5:
$ 4.50


HCP7148 aftermarket "glow-when-blown" type 15A ATC/ATO (blue) push-in FUSE, each:
$ 1.25

HCP7148SET5 aftermarket "glow-when-blown" type 15A ATC/ATO (blue) push-in FUSE, set of 5:
$ 4.50


HCP6831 aftermarket "glow-when-blown" type 20A ATC/ATO (yellow) style push-in FUSE, each:
$ 1.25

HCP6831SET5 aftermarket "glow-when-blown" type 20A ATC/ATO (yellow) style push-in FUSE, set of 5:
$ 4.50


HCP7146 aftermarket "glow-when-blown" type 30A ATC/ATO (green) push-in FUSE, each:
$ 1.25

HCP7146SET5 aftermarket "glow-when-blown" type 30A ATC/ATO (green) push-in FUSE, set of 5:
$ 4.50

 

You can add the 1982 Maxim 400 (XS400J) to this list as well. I know it ain't an XJ, but it is a Maxim. Starting to seem like the red-headed stepchild here.

 

Thank you Everyone! This is very helpful.

I will go and buy one at an autoparts store today....

I noticed the previous owner has the original panel in place, however, he bypassed it using inline fuses that are tucked away..

I would much rather have it mounted cleanly for a good visual inspections should a problem arise.

8)

 

The PO of my bike used an alligator clip on one of the glass tube fuses after one of holders broke off...I have a replacement on the way from ebay