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Author: Subject: Kawasaki electrics, HELP
paulwilson92

posted on 15/2/18 at 08:24 AM Reply With Quote
Kawasaki electrics, HELP

Are there any electrical wizards in Bristol area.

Currently on second loom and second ECU, just keep blowing fuses, have been on this for 6 weeks and it's doing my head in.

Any help would be most appreciated.

Paul 07748400025





pwilson

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russbost

posted on 15/2/18 at 08:44 AM Reply With Quote
Paul, you don't need someone who knows Kawasaki, just someone that knows wiring! You don't say which Kwak you have - do you have a wiring diagram? - if not get one, usually available on the net, without a wiring diagram the job is far harder.

If you have a circuit(s?) that blows a fuse, then there is either a short on that circuit going to earth, or there is something drawing more than the fuse can supply, neither should be hard to solve, it's just applying logic & gradually working thro' it





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paulwilson92

posted on 15/2/18 at 09:33 AM Reply With Quote
Hi, Thanks for your response,

I have a Z1000 B7, yes I have a wiring diagram and have purchased ECU and loom from USA, to eliminate immobiliser problems, I am aware of the need for a resistor in the ECU trigger and have purchased delete link for exhaust servo.
Really running out of ideas to solve this now as last night I tried unplugging all the sensors and the relays and it still blows,then tried without the ECU plugged in nothing happened at all, as I would expect.

Any ideas would be welcome.





pwilson

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russbost

posted on 15/2/18 at 10:48 AM Reply With Quote
Is it just 1 fuse that blows? If so trace from wiring diagram EXACTLY what that fuse feeds (may be more than 1 item), then trace wiring colour through to confirm it is connected to the correct place, it sounds to me as tho' possibly there is a mismatch between the loom & the ECU

I don't know much about the Z1000, but for instance the old ZX10 & ZZR1100 were almost identical engines in terms of ignition management, but you couldn't swap the ECU from ZZR1100 to ZX10 or vice versa because there were differences in the loom which affected what pins were being connected to what sensors from the ECU

Is the Z1000 similar to the Zx10R & ZZR1400 in that it has a set of relays encased in a block (looks like another ECU), the problem could lie there rather than with the ECU?





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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40inches

posted on 15/2/18 at 10:57 AM Reply With Quote
Have you wired an earth switched wire as a positive? The neutral light switch as an example. Clutching at straws really.
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paulwilson92

posted on 15/2/18 at 11:43 AM Reply With Quote
I definitely have the right loom and ECU, and allegedly the right relay box ( according to identification numbers) the only part of the loom I have used throughout is the starter solenoid and wiring links, eg main 30a fuse this is wired to a FIA master switch.
Clutching at straws again.
I will try linking loom straight to battery ?????





pwilson

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russbost

posted on 15/2/18 at 11:54 AM Reply With Quote
Paul, what fuse(s) are blowing?





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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paulwilson92

posted on 15/2/18 at 11:57 AM Reply With Quote
It's the ECU fuse everytime





pwilson

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russbost

posted on 15/2/18 at 12:07 PM Reply With Quote
Without seeing wiring diagram difficult to advise, on the ZZR1400 there is no ECU fuse, but an IGN fuse which feeds the ECU, the relay box & multitudes of other things, you need to look at the diagram & see what EXACTLY that fuse is feeding.

The ECU will normally be fed via the relay box, so I would be looking at where the feed goes when it leaves the relay box, I'm assuming that if you disconnect relay box the fuse doesn't blow?





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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Mr Whippy

posted on 15/2/18 at 12:19 PM Reply With Quote
saying all that it might be worth speaking to these guys as their in your area and do mobile call outs, after all you say you've been at this for 6 weeks...

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paulwilson92

posted on 15/2/18 at 03:05 PM Reply With Quote
That's correct, if I disconnect the relay box nothing happens, I'm off to buy a bucket load of fuses and keep disconnecting things until it stops blowing, I have a suspicion that my first option is to remove the solenoid, I'll still put a large fuse in the system and see what happens.





pwilson

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40inches

posted on 15/2/18 at 03:35 PM Reply With Quote
quote:
Originally posted by paulwilson92
I'll still put a large fuse in the system and see what happens.


Not a good idea

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russbost

posted on 15/2/18 at 04:00 PM Reply With Quote
You could put a 6 inch nail in & see which bit of wire smokes! But I don't think that's a good idea either, as I said trace the wiring from the diagram, something has to be going to earth somewhere.
The main feeds into the loom come from the solenoid, but if there was a problem from there you would expect the solenoid supply fuse to blow





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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paulwilson92

posted on 15/2/18 at 04:19 PM Reply With Quote
As I said, the only part of the whole loom that I have used throughout is the solenoid and it's links that's with both looms and ECU's, I will disconnect everything from the engine and see what happens.





pwilson

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paulwilson92

posted on 16/2/18 at 07:36 AM Reply With Quote
Spent the evening trying different combinations, ended up with nothing connected except one plug on the ECU and it still blows fuse.

The resistor fitted to the grey wire I understand is supposed to reduce voltage and be the trigger for the ECU, does anyone know what voltage that should be?





pwilson

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40inches

posted on 16/2/18 at 09:06 AM Reply With Quote
quote:
Originally posted by paulwilson92
Spent the evening trying different combinations, ended up with nothing connected except one plug on the ECU and it still blows fuse.

The resistor fitted to the grey wire I understand is supposed to reduce voltage and be the trigger for the ECU, does anyone know what voltage that should be?


Around 9volts. A 100ohm resistor. But I can't see that blowing a fuse, unless it is going to earth.
I used a 100ohm 1/4watt resistor, without the resistor everything should light up, but the engine won't start.

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paulwilson92

posted on 16/2/18 at 09:29 AM Reply With Quote
As far as I can tell from diagram and testing the ECU plugs there are two power supplies, one from fuse box (the one that keeps blowing) and one via resistor.
Q, Does the supply via resistor need to power ECU before the other supply is powered up? there are three earth leads coming from the ECU to earth point, if I disconnect these I wont get a circuit ?





pwilson

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russbost

posted on 16/2/18 at 09:31 AM Reply With Quote
When you say "fitted to the grey wire", you do mean the resistor is connected in series with the grey wire, you've not put the 100ohm resistor to earth (tho' even if you have thenthat should only draw just over 1/10 of an amp)

Are you saying that with ECU connected, but relay box not connected it still blows the fuse?





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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russbost

posted on 16/2/18 at 09:33 AM Reply With Quote
& yes, if you disconnect the earths (should all be black with yellow tracer) then you won't have a circuit





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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paulwilson92

posted on 16/2/18 at 09:42 AM Reply With Quote
That's correct, ECU connected and relays disconnected, still blows fuse !





pwilson

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russbost

posted on 16/2/18 at 10:16 AM Reply With Quote
Are all the earths black with yellow tracer - if not one of them isn't an earth!

Does the ECU have 2 plugs to it? If so disconnect one & see if still blows fuse, then disconnect the other & try, you now know which plug the problem is on, you need to look at wiring colour from fuse that blows (make sure you are looking at output side) & check where that wire is going to on the ECU

If you use the wiring diagram this really should be a fairly simple exercise





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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paulwilson92

posted on 16/2/18 at 10:40 AM Reply With Quote
Yes, the ECU has two plugs and with just one plug connected it still blows fuse, I have pulled plug off and tested for power from each connection and the only power supply is from white/ black trace which comes from fuse box ( the one that's blowing)





pwilson

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russbost

posted on 16/2/18 at 11:45 AM Reply With Quote
so when the ecu goes live it is feeding power to one of the wires you currently have connected to earth would be my guess; disconnect all 3 earth wires,, fit the fuse & assuming it doesn't blow then connect the single ECU plug that you have the problem on & then touch each of those "earth wires" to earth, 2 will probably be fine the 3rd will spark & if you do more than flash it across to earth will blow fuse. If you're going to be making sparks make sure there is nothing flammable to hand!

If you are saying that it blows the fuse even with all other sensors & relay box disconnected then I can't see it being anything other than one of those 3 wires you have as earths





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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paulwilson92

posted on 16/2/18 at 11:52 AM Reply With Quote
I was thinking that was my next move, once I've identified the earth that's shorting I will trace it back to it's origin and check for resistance/ continuity etc.
I'm guessing that if the ECU has three earths that it needs all three to work correctly ?





pwilson

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russbost

posted on 16/2/18 at 01:50 PM Reply With Quote
probably not, sometimes additional earths are simply "insurance" or to help counter any interference from other circuits, but I have a strong suspicion you may find one of those 3 isn't meant to be earthed at all!





Furore Formula Car - the only two seater modern Formula Car lookalike. I no longer run Furore Products or Furore Cars Ltd, but would still highly recommend them for Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, user names furoreltd & furoreproducts, discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

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