This is a How-To on replacing the oe fuse box with a more reliable aftermarket ATO-style fuse box. Before we get started, we'll need to collect a few pieces. We'll need a fuse box. I picked mine up from the CARQUEST store where I work. It's a reboxed Littelfuse brand going by the part number 350417BP



In addition, you'll need a couple of mounting screws (8x1"), electrical tape, a couple zip-ties, a box of female insulated spade terminals, and fuses (ATO10 amp x 3 & ATO20 amp x 1).

Tools? Phillips Screwdriver and Wire Cutters/Crimpers/Strippers.

Okay... Ready? Here we go. Let's meet the patient:



My wife's '82 XJ650J Maxim.

Here are the steps...
1. Remove Seat.
2. Remove Right-Hand Access Cover exposing battery.
3. Disconnect battery.
4. Unscrew old fuse block.



5. Note fuse sizes and wire colors.



6. Pry open metal wire retainer ring at the base of oe fuse box.




7. Place zip-ties around left- and right-hand wire bundles and unwrap tape.
8. Cut wires at crimp joints.
9. Take new fuse box and position it for mounting, making sure all the wires will reach their respective terminals.
10. Strip wires and install female insulated spade terminals.



11. Tape wires bundles and attach terminals to fuse box.
12. Using the two #8x1" screws, mount the fuse box.



13. Install fuses and dust cap.



14. Reconnect the battery.
15. Install side cover and seat.

That's it. You're done!

(Editor's Note) It occurs to me that if you have a tool caddy you'll want to make sure you allow room for it



Notice how I've bent the spades a little to make the connections a little more convenient. I still need to label the fuses. From left to right, they're 10A IGNITION, 10A SIGNAL, 10A HEAD L., and 20A MAIN.

(Written by Don Bangert Author of several How-To's and the blog, The Path Less Traveled.)