1. Dismiss Notice
  2. Hey Facebook people... We've created a group for XS650.com members to connect. Check it out!
    Dismiss Notice

Jim's 1980 SG Restoration. And Yeah.... A Few Mods.

Discussion in 'The Garage' started by Jim, Sep 26, 2017.

  1. Paul Sutton

    Paul Sutton Buckhorn Gang Member Top Contributor

    Geedubya, there are various alternatives to replacing/repairing the stock 4 fuse box. Ebay is a good starting place. You will note from this thread that for Jim's new fuse box to work he will try to isolate one of the fuses. This approach will be quite tidy because there will only be a red and brown input and 4 output wires. Lets hope Jim is successful and I am sure he will be.

    The following link is to a similar fuse box which has 4 totally independent fuses:
    https://www.ebay.co.uk/itm/4-Way-Ca...968312?hash=item2cc3f1dab8:g:d2EAAOSwxixaGUC1
    I originally tried this one but in my opinion it looked untidy by the time I had fitted 4 inputs and 4 outputs. Also it was too high to fit nicely under my SH's seat. So do measure up well and buy a fuse box that will fit nicely in the space available.

    In Entry 252 above Downeaster showed where he fitted his fuse box with 4 independent fuses and it is very tidy. On my SH this position is not available for use because the airboxes fill the entire space.

    I eventually bought a modern copy of the XS650 fuse box from Ebay:
    https://www.ebay.co.uk/itm/Yamaha-N...640090?hash=item3624438a5a:g:6LsAAOSwal5YCdxf
    The difference between these models just seems to be the fuse values and where the wires exit the box, but this adjustment is easily made.

    Others have also used 4 individual blade fuse holders.

    If you want some extra life out of your stock fuse holder then carefully remove the clips and put a thick layer of solder in the bottom corners where the brass tends to crack.

    A very interest repair was made by Vlad where he replaced the old clips with new (See Entry 27):
    http://www.xs650.com/threads/vlads-restoration-project-w-pics.34595/page-2#post-517124
    The supplier details as given.

    Best of luck.

    Edit: See Ebay Australia for XS650 fuse box
     
    Last edited: Dec 28, 2017
    geedubya and Jim like this.
  2. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    I got it off of Amazon.
     
    geedubya likes this.
  3. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    I don't think they teach science in school anymore....
    Just went to the store to get a fresh propane bottle to warm up the garage.
    "I'd like to swap out a gas bottle please" I said to the millennial behind the counter.
    "Propane?" she asks...
    "Nah... think I'll try the hydrogen this time" I said.
    She pulls her flip cards out and starts flipping through them. After bout' 30 sec. she starts looking around for a manager and says "I think all we have is propane. Let me ask the manager....."
    "That's OK, I'll just take the propane."

    Kids.... ;)
    MVIMG_20171228_155410.jpg
     
    Griz, drgonzo, jradvantage and 6 others like this.
  4. Mailman

    Mailman Hardly a Guru Top Contributor

    Hey! A hydrogen heater could be ...a...a......probably not good. :D

    That is unless you wanted a whole bunch of heat......RIGHT NOW!
     
    shortTRIP, robinc and Jim like this.
  5. Mailman

    Mailman Hardly a Guru Top Contributor

    " Fill er up, with hydrogen , please! "
    image.gif
     
    xjwmx, Griz, jradvantage and 3 others like this.
  6. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Oh the humanity.....
     
    MaxPete likes this.
  7. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. XS650.com Supporter Top Contributor

    James....you get right back in the house this instant young man - and stop teasing that nice young girl at the store!!!!

    37078E01-FBBB-40C3-BE2B-9E7F78AD0EB7.jpeg

    .....and then you made me snort with the line from the Hindenburg broadcast.
     
    azman857 and Jim like this.
  8. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    So, the fuse box showed up today. Like any red blooded 8 yr. old, first thing I did was take it apart. In my excitement, I forgot to take some pics... so bare with me here....
    It was easy to disassemble and, as I suspected, pretty easy to isolate one of the fuses. All it took was a pair of dykes (why do we call them pairs? there's only one....).

    MVIMG_20171229_140116.jpg


    MVIMG_20171229_141632.jpg

    After numerous rabbit holes that I won't go into, I decided to drill through the tab I cut off and insert the feed wire from the back....

    MVIMG_20171229_153119.jpg


    MVIMG_20171229_153130.jpg


    Soldered the wire to the cutoff tab and soldered a small black wire to go to the circuit board to complete the LED circuit....


    MVIMG_20171229_154750.jpg


    Soldered the black wire to the main chassis and cut a pathway in the backside for the feed wire...


    MVIMG_20171229_155057.jpg


    Epoxied the wire into the cutout....


    MVIMG_20171229_160927.jpg


    Reassembled... and here we are. A fuse box with a power feed to a single fuse (1) and a separate (original) feed to the other 3 (2, 3 and 4) fuses.


    MVIMG_20171229_200612.jpg


    I think that I'll get some RTV tomorrow and fill the inside for added vibration protection. I'm gonna order another one for a spare and I promise, I'll take more detailed pics when I mod the next one.
     
    Last edited: Dec 29, 2017
    Curt, Paul Sutton, MaxPete and 2 others like this.
  9. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. XS650.com Supporter Top Contributor

    Very nice Jim - that should work well!
     
    Jim likes this.
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    I like it Jim! Very stealthy.
     
    Jim likes this.
  11. Griz

    Griz XS650 Enthusiast

    I’m not quite a millennial but I did miss a lot of science classes...what’s the point of isolating a fuse? Also, Forgive me for not reading the entire post. There were too many words and not enough large colorful pictures:doh:
     
    WBacon and Jim like this.
  12. Paul Sutton

    Paul Sutton Buckhorn Gang Member Top Contributor

    Griz, this is a 4-way fuse box with one power input at the screw/nut supplying 4 outputs via the 4 fuses.

    The wiring for the XS requires 1 fuse between the rectifier/regulator power output and the battery (red wire). The isolated fuse does this and as a conseqence the 4-way is now reduced to a 3-way fuse box.

    The red wire also carries power to the ignition switch. When switched on power is supplied from the ignition switch on a brown wire back to the 3-way fuse box where it connects to the screw/nut which is common to the remaining 3 fuses. These 3 fuses now give power to the red/white, red/yellow and brown wires for the various systems connected to the harness e.g. red/white is power to the ignition system.

    Shorter Version: We have just butchered the 4-way fuse box to create a single inline fuse and what remains is now a 3-way fuse box to power the bikes systems.
     
    Griz, TwoManyXS1Bs and Jim like this.
  13. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    Those connector tabs and the way they stick out into space bother me, just one of my quirks, like bungee cords and antique furniture. Hard wired and removing the connector tabs would make those fuse boxes less of an after thought, like a short harness and one multi-connector to tie into the harness.

    Scott
     
    MaxPete and Jim like this.
  14. Paul Sutton

    Paul Sutton Buckhorn Gang Member Top Contributor

    Mrtwowheel, I viewed the connectors as being a bit untidy original but they looked a lot nicer with 90 Degree spade connectors. The straight spade connectors made the wires stick out too much.
     
    Jim likes this.
  15. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Update on the fuse box.
    A very intelligent electrical engineering buddy of mine pointed out to me that I needed to remove the black wire I installed so that I don't power the three 10A fuses with the key off. So I removed it and tested it with a trouble light....


    MVIMG_20171230_145837.jpg

    As advertised, the LED lights up when you pull the fuse. So, I filled it with RTV and put it back together.... ready to install. The main feed LED doesn't work, but a completely dead bike would be a good indicator to check the 20A fuse;)
    Thanks Paul:)
     
    Curt, Griz, TwoManyXS1Bs and 5 others like this.
  16. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. XS650.com Supporter Top Contributor

    Very nice!
     
    Jim likes this.
  17. Griz

    Griz XS650 Enthusiast

    I have been informed. The fog of ingnorance is not so thick anymore. It’s still pretty heavy though. I’ll keep reading posts:umm:
     
    Jim, YamadudeXS650C and Paul Sutton like this.
  18. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Fabricated the plate for the fuse box today. Cut from .063 aluminum sheet....


    MVIMG_20180101_184813.jpg

    Riveted on a couple of floating 10-32 nutplates for the box.....


    MVIMG_20180101_184751.jpg


    A little OCD treatment.....


    MVIMG_20180101_200715.jpg


    And put it all together....


    MVIMG_20180102_144452.jpg


    MVIMG_20180102_144445.jpg


    Now I gotta' wait for my 90 deg. terminals to arrive so I can wire it all up.
     
    Curt, MaxPete, Mailman and 2 others like this.
  19. Downeaster

    Downeaster Everything in XS Top Contributor

    Nicely done, Captain.
     
  20. Paul Sutton

    Paul Sutton Buckhorn Gang Member Top Contributor

    Nicely done and a fine touch with the pits filled with molten silver then polished. I like the way to tied the Br, R/W and R/Y wires together rather than trim them out - preserves your options sometime in the future??

    Edit: I like the polished stainless steel bolt heads.
     
    Jim likes this.

Share This Page