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Best Fuse box upgrade 21 Apr 2014 14:22 #629878

  • diego092409
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My Easter Ride yesterday turned into a fiasco thanks to a blown main fuse. My 1982 KZ1100 B2's fuse has been needing replaced for as long as I can remember. The clips for the 30A main fuse get loose and the fuse blows.

I am toying with the idea of a wholesale replacement of the fuse box to upgrade to blade style fuses. Has anyone else taken a fuse box from a new bike and installed it on their KZ? I am thinking of something like the fuse box on my concours or something like from a newer ninja that which will fit under the side cover. I would like to relocate it under the right side cover to make for easier access to it without having to remove the seat. This is just one of myriad of upgrades that will need to be made to make this thing shine to its true potential.
1982 KZ1100 B2 - 'Old Red' kzrider.com/forum/11-projects/601185-gpz-1100-resto-mod-old-red
2015 BMW K1600GT
2017 KTM 690 Enduro R
2018 Kymco Spade (wife's)

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Last edit: by diego092409.

Best Fuse box upgrade 21 Apr 2014 19:03 #629906

  • MFolks
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Fuse And Fuse Holder Designations

1. The older Kawasaki’s use a glass tubed fuse with the designation of AGX 1” long. Most good auto parts stores can get them for you. They are ¼” in diameter.

2. The more common AGC is 1 ¼” long and may not fit the smaller fuse clips. Again, ¼” in diameter.

3. To clean and polish the fuse clips, I use a cotton swab(Q- Tip) and some Brasso metal cleaner or Turtle Wax Chrome Polish. I suppose any good metal polish would work.

4. These fuses can fail internally but look good, only by removing them from the clip and electrically continuity checking with either a self powered test light, or a multimeter set on OHMS can they be determined to be in good shape. Also checking for voltage through the fuse, is another way to determine if it's good.

5. A physical inspection of the metal end caps for tightness will tell you if the fuse is serviceable.

6. Most modern motorcycles are now using the automobile “Blade” style fuse with the designation of ATC or ATO.

7. The reduced sized “Mini” Blade style fuse holder uses the ATM size of fuses.

8. If the fuse and fuse holder overheat, it could soften or anneal the grip of the clip, it might require squeezing the clip to restore the tightness.

9. A list of where to purchase “Blade” style fuses and holders:

www.waytekwire.com order.waytekwire.com/productdetail2/M50/...20%20%20%208%20FUSE/

www.rallylights.com www.rallylights.com/detail.aspx?ID=765

www.delcity.net/store/6!way-fuse-blocks/p_10822.a_1

10. A source for the glass tubed AGX fuses:
www.boatownerswarehouse.com/browse.cfm/2,4986.html
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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Best Fuse box upgrade 22 Apr 2014 01:48 #629933

  • Patton
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1973 Z1
KZ900 LTD

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Best Fuse box upgrade 22 Apr 2014 03:29 #629937

  • diego092409
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I have looked at the eastern beaver and other fuse holders out there. They seam that tehy are more geared for use as auxilliary blocks. Although after clicking on that link, it appears to be getter suited with the 30 A main fuse relay upstream of the block.

The existing fuse block is in rough shape. Before I unwisely tore it down 10 years ago, I would be springing the main fuse clips together to get better contact and it worked fairly well. Last year as I was putting it back together finally to run, I made contact somehow and overheated some of the wires (melted coating, wire still good) plastic around the main fuse holder melted and looks pretty rough, I would like to change it out completely, I bought a fuse box off of ebay for a spectre but it was in almost as bad as shape and the wasn't a direct replacement.

The other reason, I am wanting to locate it under the right side cover is because, I am planning the installation of a shock mount where the battery is currently located and to make room for the battery, I am considering removing the center section of airbox duct that the fuse box is mounted on and the air temp sensor is mounted and putting K&N type cone filter right onto the surge box so make room for a small Lithium Ion battery.
1982 KZ1100 B2 - 'Old Red' kzrider.com/forum/11-projects/601185-gpz-1100-resto-mod-old-red
2015 BMW K1600GT
2017 KTM 690 Enduro R
2018 Kymco Spade (wife's)

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Best Fuse box upgrade 22 Apr 2014 03:59 #629939

  • diego092409
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Another questions, does anyone know how to remove the existing wires from the main disconnect plugs so that I can reuse it when I am replacing the box?
1982 KZ1100 B2 - 'Old Red' kzrider.com/forum/11-projects/601185-gpz-1100-resto-mod-old-red
2015 BMW K1600GT
2017 KTM 690 Enduro R
2018 Kymco Spade (wife's)

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Best Fuse box upgrade 22 Apr 2014 05:22 #629943

  • 650ed
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diego092409 wrote: Another questions, does anyone know how to remove the existing wires from the main disconnect plugs so that I can reuse it when I am replacing the box?


Please show a picture of the parts in question. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Best Fuse box upgrade 22 Apr 2014 06:39 #629948

  • martin_csr
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cwswiring.com - Fusebox Wiring Harness - FH-01

cycleterminal.com - Tools

If you need to do some terminal crimping, I would use open barrel terminals & install them w an open barrel crimper (the crimps are very strong = good connections)(doing so is the same as stock). If you already happen to have a Harbor Freight ratcheting crimper, you can get replacement open barrel dies for making the proper crimps.

Another handy tool to have is a terminal pin extrator. The white handled set in the tools link above is what I used when I replaced a voltage regulator.
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Last edit: by martin_csr.

Best Fuse box upgrade 22 Apr 2014 08:45 #629956

  • kaw-a-holic
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I swapped mine out with no issues using the 6 slot blade style block. No problems with the 30 amp fuse. All I did was cut off the stck ends and crimp on blade style female ends. I soldered mine on then used shrink tide to protect them.
Jon
1977 KZ1000a1
Mesa, AZ
Phoenix Fighter Project

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Best Fuse box upgrade 30 Oct 2014 04:25 #652184

  • diego092409
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I have decided to go with the Painless performance 7-circuit switched fuse box and it has been a challenge to get it shoe horned in some place. I had to bid and underseat tray. I am hoping that with the forthcoming swingarm swap and the smaller wheel in the rear, there wil be less chance for it strike the tray. There is 3" of clearance as it stands.

My revised question is the following, has anyone successfully adapted a modern fuse/relay box to service all of the different systems on the bike? Is there a modern ZX fuse box that has the fuel pump, turn signal, brake light, headlight and starter relays already mounted in them? I look at the old relays on my bike and I have to believe there is something smaller, more compact to service all of the different things that need to happen.
1982 KZ1100 B2 - 'Old Red' kzrider.com/forum/11-projects/601185-gpz-1100-resto-mod-old-red
2015 BMW K1600GT
2017 KTM 690 Enduro R
2018 Kymco Spade (wife's)

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Best Fuse box upgrade 30 Oct 2014 06:12 #652201

  • 531blackbanshee
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i am currently saving my pennies for one of these. :evil:

www.phatperformanceparts.com/Motogadget_...er_p/moto-m-unit.htm

pi$$ on fuses .

leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
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Last edit: by 531blackbanshee.

Best Fuse box upgrade 30 Oct 2014 13:00 #652244

  • diego092409
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I saw that after I had bought the painless performance fuse box and have been kicking myself ever since...

I am wondering about all the relays. I figure I need the ones that I mentioned. I didn't know if modern relays were smaller or not...
1982 KZ1100 B2 - 'Old Red' kzrider.com/forum/11-projects/601185-gpz-1100-resto-mod-old-red
2015 BMW K1600GT
2017 KTM 690 Enduro R
2018 Kymco Spade (wife's)

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Best Fuse box upgrade 31 Oct 2014 04:21 #652366

  • diego092409
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Now upon closer inspection I realize, this is what I want... I am not lusting for an M-unit too...
1982 KZ1100 B2 - 'Old Red' kzrider.com/forum/11-projects/601185-gpz-1100-resto-mod-old-red
2015 BMW K1600GT
2017 KTM 690 Enduro R
2018 Kymco Spade (wife's)

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