Yamaha 900 Diversion - rubber (TPU) Fuse holder

This design replaces the rubber support of the fuse holder on the Yamaha 900 XJS Diversion, which deteriorates over time.
I also rebuilt a hinge (which was broken) for the small fuse holder (paste it with cyanoacrylate glue).
Produced on an FDM printer using TPU Flex, 0.4 mm nozzle, 0.2 mm layers.

For the printing, I activated the supports with these settings: angle > 50° and only in contact with the plate. There is only one small print support, you can do without it if your printer handles bridges well.

This design was created using SketchUp 2017; the source file is attached.
The STL files for the rubber support and hinge are also attached.

Operation :

Caution: disconnect the negative terminal of the battery before proceeding.

To replace it, first remove all the wires from the plastic fuse holder.
Unclip the connectors using a small screwdriver, as shown in the photo. Apply slight lateral pressure to the clip pointed to by the screwdriver while pulling the wire downwards.
Repeat this operation for all wires. It is best to have two screwdrivers for the double connector (see diagram in the ‘Fuse holder.pdf’ file).

Then remove the two plastic fuse holders from the rubber holder.

To reassemble, follow the steps in reverse order.
Do not forget to reconnect the negative battery terminal (:-D).
Reminder: the ‘Fuse Holder.pdf’ file contains a diagram showing the wire colours, the amperage of each fuse and their use.

For the hinge, file down the broken pieces and file down the piece that sticks out on the fuse holder a little more so that it is aligned with the side of the cover. Then degrease thoroughly, leave to dry and glue the hinge in place using cyanoacrylate (see photo).

Enjoy!
papat400.