Adding a Blue Sea 6-Circuit Fuse Box -- Part One

(DISCLAIMER: These articles are simply records of what I've done, and the results thereof. You work on your own bike at your own risk. If you blow yourself up, destroy your bike, cause the neighborhood to erupt in a ball of fiery death or whatever, it is NOT MY FAULT.)


If there's one thing I hate, it's buying a bike with a rat's nest of electrical wiring that's usually all one color, is all over the place with no rhyme or reason, and is just slapped together with wire nuts and no fuses. If you're going to do something, do it right.

Since I plan to install a bunch of electrical accessories ("farkles") on Diana, I decided to start with a good base: a Blue Sea fuse block, available from 2wheelinnovations.com. Along with this, you'll need:

An inline fuse holder, rated for 30 amps, available from your local Radio Shack. You can use a standard or mini-blade type--it matters little. I used the standard size, simply because mini-blade fuses might be harder to find on the road. We'll be using a 25-amp fuse in this holder.

A 30-amp, 12vdc relay, also available at RS.

A basic electrical kit, including wire cutter/strippers, female spade connectors in 18 and 10 gauge sizes, 10 gauge ring terminals and 18 gauge U-terminals.

10 and 12mm sockets, a 3" extension bar, and a pair of pliers.

A drill and bits, slotted and phillips screwdrivers, and a couple of cold ones.

Ready? Here we go.

This is the Blue Sea Fuse Box with the cover on, and a 10 gauge ring terminal attached to the positive and negative posts.


This is the inline fuse holder and the relay we'll be using. A 25-amp fuse is already installed in the holder.

Here is the Fuse Box with the cover off. Notice that there are six positive terminals with fuse receptacles, and six ground terminals. This way, you don't have to run a mess of ground wires to various bolts on the frame and make a mess of the whole thing.


Are we ready to rock? Alright, then...