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Fuse Box 30 Amp blade removed stopped noise!

Trojan441 Oct 22, 2019

  1. Trojan441

    Trojan441 Well-Known Member

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    Cleaned everything @ the weekend, but getting a strange noise from behind the Fuse box, pulled out a green 30 Amp blade fuse n' it stopped! Now. rushing off to an appointment anyone had a similar issue ever? Probably a temporary short going on?
     
  2. R. J.

    R. J. Supporting Member

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    :hello: I'm not positive on your bikes fuse box set up. Take the fuse box apart and check for rust/corrosion or you may have gotton it wet. You may have a bad relay.
     
  3. Trojan441

    Trojan441 Well-Known Member

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    Cheers R.J, just got home, 30 Amp is the Main fuse according to the ZL 600 Electrical diagram. The ZL 400 diagram is in Japanese n' doesn't magnify well in detail! I cleaned n' sprayed everything at the weekend to get ready for the Winter! So perhaps some dirt has been disturbed, if it is fine n' not raining, I will have a look @ it 2morrow! The intermittent noise was a buzz with like a mini-speaker small horn sound, so could be a combination of stuff! If I think back, a few strange things have happened, since I fitted an over-ride switch to the Fan circuit so I will start there n work back to the Fuse box!

    In think there are only two Relays, The Indicator Relay & the Starter Relay, everything else is switched & fused with Blade type fittings.
     
  4. R. J.

    R. J. Supporting Member

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    :hello: The ZL 900 has 2 or 3 relays in the fuse box that can be unplugged.
     
  5. Trojan441

    Trojan441 Well-Known Member

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    Bigger bike, bigger price, bigger equipment maybe!
     
  6. R. J.

    R. J. Supporting Member

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    :hello: The ZL 1000 fuse box is different. If it has relays in it they are soldered in.
     
  7. Trojan441

    Trojan441 Well-Known Member

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    Spray cleaned Junction box, but made no difference, still making a noise , so I will have to open it up. Until I stopped running the machine n' doing other maintenance jobs this wasn't a problem! Anyone opened a Junction box up? Fixings are not conventional; screws.
     
  8. Trojan441

    Trojan441 Well-Known Member

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    20191105_195257.jpg 20191105_195325.jpg Opened Fuse-box junction box,n' damaged through wet, U were right RJ there are some tiny relay blocks in there . They are identified as NEC Japan -x & NEC Japan -w, the third position is empty, the circuit board is numbered 5000-9923 and has TD on it presumably the manufacturer. The circuit test intact, but a hole is burnt through the board!
     
  9. R. J.

    R. J. Supporting Member

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  10. 87kawzl

    87kawzl Supporting Member

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    Glad she didn't burn down, that's ugly!
     
  11. Trojan441

    Trojan441 Well-Known Member

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    Me too! We have had an exceptional wet Autumn n' I suppose when other repair work was going on the damp got in there! I had lost the strip that fitted over the fuses, so that probably didn't help either!

    Let this be a warning to others to keep on top of electrical maintenance! In drier country's, perhaps not as critical a problem as in the wet n' often damp British Isles!
     
  12. R. J.

    R. J. Supporting Member

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    :hello: That's why I don't wash my bike with a garden hose. If it's dusty I blow it off with 90 PSI of air with a nozzle which has a rubber tip. Then I use a damp micro fiber towel cleaning it often as I go.
     
  13. Trojan441

    Trojan441 Well-Known Member

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    Cheers Rj, have trawled through the Ebay stuff, 26021 it seems is the physical form of the /Junction/Fuse box, then the last four digits follow, the ZL600 is 26021-1056, the ZL 400 is 26021-1057, have looked also @ cross-Compatibility to other Kawasaki models of this period. The Main variation is later machines have six bladed fuses in the circuit rather than four! Screenshot at 2019-11-06 11:06:41.png Screenshot at 2019-11-06 11:08:46.png
     
  14. R. J.

    R. J. Supporting Member

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    :hello: So the one from the ZL 600 will work. If you can't find one on your side of the big pond and if you need someone to buy one over here I can buy it for you. Then I can ship it to you if need be. I do have a paypal account.
     
  15. Trojan441

    Trojan441 Well-Known Member

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    Thank you RJ, I have found a 400 one n' ordered it n' a 600 one too. This is the biggest problem with technology on bikes, what happens when we can't get bits n' pieces anymore, my British stuff has no tech that will keep it off the road, all component parts can be easily replaced, I suppose the earlier Harley's were like this too!
     
  16. Trojan441

    Trojan441 Well-Known Member

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    Me too!
     
  17. R. J.

    R. J. Supporting Member

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    :hello: That's good that you found some. It might be a good idea to open them up for inspection and cleaning. That is if you can without damaging them. Check them for loose and or cold solder joints. Clean off any corrosion with a small nylon brush.
     
    Trojan441 likes this.
  18. Trojan441

    Trojan441 Well-Known Member

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    Yes getting in them without damaging anything is a mite tricky!
     
  19. R. J.

    R. J. Supporting Member

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    :hello: I had a fuse box that had 3 resistors. Each one had no solder on 1 leg/stem. They had corrosion on them and one was arking. When this happens it causes the PWB to short out. Sort of what happened to yours. Also cold solder joints can do the same. Corrosion = higher resistance.
     
  20. Trojan441

    Trojan441 Well-Known Member

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    PWB = PCB over this side of the pond! Printed Circuit Board. Presumably the same "Board 5000-9923, was used on many other models?
     

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