EDIT - Switching to a mini 12 volt 30 amp circuit breaker. Will fit in the same housing as the mini fuse.
Purchased an inline mini blade fuse holder from an auto parts store, I think it was Autozone. Price was around $3.00.
Removed the starter solenoid which has the dogbone fuse holder attached to it from the bike to make it easier to work on. Remove the screws and lay dogbone aside.
Start to prep the fuse housing to accept the wiring for the new mini fuse holder. You still want the lid to close after installing the mini fuse holder wiring. Start out with a 1/4" drilled hole.
I found it easier to work with the wires if I continued the holes into a slot.
Lay out the wiring over the old dogbone location, mark and then cut your wires to length. Then prep for installation of wire ends with a hole big enough to accomidate the old dogbone screws. Cut the correct size shrink boot and slide onto the wires prior to attaching the wire ends.
Before making the crimp on the wire ends remove the plastic sleeve (made without but these were all I had) and then prepare the wire end for soldering after the crimp is made. There are more ways to prep for soldering than I'm going to go into here. My way is to rough up the wire end where I intend to solder using a small metal file. Then I crimp the wire more for holding purposes than any other reason.
One other thing I do when soldering is to use solder that does not contain any additives. I add a bit of solder flux to both ends of whatever is being joined together and have never had one come apart.
Slide up the shrink boot as far as it will go (there is some shrinkage) onto the wire end. Use a mild heat source, preferably something without a flame and shrink the material around the wire and wire end.
Install the wire ends onto the location where the dogbone used to be using the screws that were holding the old dogbone, install your new mini 30 amp fuse into the proper location and close the cover and re-install onto the bike.
Once the solenoid is installed back into it's original location I used a plastic tye wrap to secure the mini fuse holder in place. Wasn't necessary to use the tye wrap but as rcmatt007 pointed out to me .... I have OCD
This was all done in 09 and is still working fine. The only thing I would do differently is get one that has a spot for a spare fuse built into the housing.
)
