Finally found a decent fuse box:

I'd seen other threads on the subject, and I even bought a blade type fuse box, but the way the terminals are arranged on each side of it, I couldn't figure out a way to mount it without moving a bunch of stuff and fabing brackets and such.
But I found this website that held the answer: www.easternbeaver.com/Main/Elec__Product...ers/fuseholders.html

It's the Metri-Pack 280 3 Fuse Fuseholder for ATM Type Mini Blade Fuses.
Weather tight and it holds the mini blade fuses, and it fits right where the stock unit was.
Only problem is, the dude wants a twenty dollar minimum purchase. So I bought two, some extra fuses and some extra bullet connectors for other stuff.
Another thing is, the crimp terminals don't form very well with my cheapo Autozone wire crimpers, so bear that in mind.

Nice! Thanks for the link. I may get a couple of these myself

riverroad would you mind postin some pics of your install?

i would like to do this myself.

are you interested in selling the extra one you bought?

leon

That looks perfect! Please post some photos of your conversion.

Oh and noob question here, but what's the two different versions? 18-16 AWG and 14-12 AWG

Is that the wire gauge? And if so, anybody know what we've got in these old KZs?

Well, I haven't taken any pics of it yet, but there really isn't much to look at when trying to compare the old and new. They're both the same general size and shape, and it fits in the same place the old one did. But I haven't figured out how to attach it to the rubber thingy yet. I might take some pics tonight when I get home, but I'm working hard on my 54 F100 right now too. (I hate body work!)
Think I'll keep the extra one though. Might add some extra circuits one of these days, Heated grips, stuff like that.

Eastern Beaver Fuse Box

Nice link!! I see a couple of things on that site i've been looking for! This should kill my distrubution & grounding issues in 1 tidy go!

www.easternbeaver.com/Main/Products/Fuseboxes/PC-8/pc-8.html

Wire Termination Insulation & Sizes

Terminal Insulation Color Wire Sizes
RED

---

22-18 gauge wire
BLUE

---

16-14 gauge wire
YELLOW

---

12-10 gauge wire

The ring terminal holes comes in many sizes, from #4 up to 1/2" in most cases, it's a matter of finding the tightest fitting hole to fit the fastener for the termination.

American Wire Gauge(AWG) is backwards to what many people think; that is 22 gauge is many times smaller than 10 gauge even though the number is bigger.


If you need information about heatshrinkable terminals, or splices(butt connectors) and tools, just ask....

In reply to what he wire sizes are used in the Kawasaki's, it depends on the current(amp) needs.
Most lighting circuits are at least 18 gauge in size, but can be 16 gauge(like for the brake/running light circuit). Battery cables are probably 8 gauge for the high current draw when starting turning the engine over.

The white with red strip wire from the regulator/rectifier to the battery is probably 12 gauge in size.

I'd say using at least 18 gauge for lighting circuits is a safe size. with 16 gauge if more current draw is anticipated. 12 gauge for most high current draws in 20 and 30 amp fuses should be safe.

Okay, MFolks, is that box in the link above a good solution for me? I'll be running a Headlight, Tial/stop light, horn? I'll be running all the gnd/pwr wires from inside a fabricated alu box under the seat as i want to keep the wiring out of sight. There will also be wires to & from the clock (an Acewell clock www.acewell.co.uk/Acewell%20Speedometers/ACE-2xxx/index.htm ) & a nautral & oil light on the clock

Depends on how weather protected it is, as moisture will play havoc with electrical circuits.Myself, I like the fuse blocks/holders with some protection from splashes/drips.

Here's another website about wiring on the bike using relays:
www.canyonchasers.net/shop/generic/relay.php

Marine rated fuse blocks(not sure if the circuits are seperate for motorcycle use)
www.iboats.com/Blue-Sea-SafetyHub-150-Fu...8312--view_id.729804

www.iboats.com/Seachoice-ATO-ATC-Fuse-Bl...748312--view_id.2901

www.iboats.com/Screw-Terminal-Blade-Fuse...8312--view_id.163740

www.google.com/products/catalog?rlz=1T4D...AQ&ved=0CIQBEPMCMAU#

bluesea.com/category/81/21

Check the bike's wiring diagram(or if possible open up the back of those fuse blocks with backs to check for jumpers or buss bars tying several circuits together).Kawasaki's did this to reduce some of the wiring.