ZL 900/1000 Fan Circuit Testing Trouble-Shooting & Repair

:hello: Found this muzzy fan. It's for KAWASAKI 1996-2002 800 DRIFTER. $100 shipped. :laughing7: . https://www.ebay.com/itm/155279517654 . Today I mounted my radiator and shortened the wiring for my Daytona Meters digital tach, temp gauge and volt meter. They was about 6 feet long. I had them rolled up under the fuel tank temporarily for 5 years. :laughing7:. ________________________________________________________________ 20230425_195149[1].jpg 20230425_195227[1].jpg
 
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:hello: I stand corrected on how many blades are on a ZL9/10 fan assy. It has 7 blades and not 4. The CONNIE's fan has 4 blades. I didn't know I had this spare fan Assy. Yesterday I put coolant in my ZL 10. Also before installing my fan assy. I installed a new 97* C part # 27010-1180 fan switch with black lead in the bottom rear of the radiator. Started my bike and the fan is still not coming on. :angryfire:. So I need to do more trouble-shooting. :pain10:. 20230427_085352[1].jpg 20230427_085312[1].jpg 20230427_085456[1].jpg 20230427_092533[1].jpg
 
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:hello:FURCHIN helped me out. I bought a CARQUEST radiator cap part #10233. $14. See pic #4 for aftermarket and OEM part # for the radiator cap and the thermostat. I ohmed out the fan circuit wiring and put dielectric grease on all the connectors. All checked out good. I'll finish tomorrow.20230427_164001[1].jpg20230427_092533[1].jpg 20230427_165755[1].jpg20230427_175028[1].jpg
 
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:hello: Today I finished up the problem on my ZL 10 with the fan not coming on. The round relay was bad. I'm now down to 3 spares. :laughing7:. 20230428_170233[1].jpg 20230428_170304[1].jpg
 
:hello: First I checked the fuses. Secondly I ohmed out the wiring to make sure I had no open wires or high resistance. Then started the bike. The fan still did not come on. Replaced the round relay. The fan came on as it should. Then I put the old relay back in and the fan didn't come on.
 
:hello: While I'm not completely done. My fan isn't coming on while the bike is running. I never did let the bike reach 230*F when I was trouble-shooting the fan circuit. So onto the fan relay circuitry. First I checked the fuses. Ohmed out the wiring and checked for high resistance. All seems good. I installed a new square fan switch relay. Still a no go. Next I installed a new 230*F green/white thremo switch. Still a no go. Next I unpluged the fuse box and checked for resest pins. Since I had the fuse box out I installed my spare fuse box that KAWBOW refurbished dated 09-17. Part # 26021-1062. The one I took out was also refurbished by KAWBOY on 03-13. Part # 26021-1060. It had solder on some of the pins so I scraped it off. Going to start the bike and test for fan on at (230*F) while the bike is running after dinner. :laughing7:. __________________________________________________________20230429_175916[1].jpg20230429_190125[1].jpg 20230429_180128[1].jpg 20230429_180200[1].jpg 20230429_181126[1].jpg 20230429_181100[1].jpg 20230429_164131[1].jpg 20230429_164531[1].jpg 20230429_164257[1].jpg
 
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:hello:I'm still going through my wiring harness. The fan is still not coming on while the bike is running. :angryfire:. :banghead:. :cussing:. I've been looking here on the fourm for the thread for the by pass switch that wires into the relay itself which is supposed to allow the fan circuit to operate as it should. Does anyone know how to do this or know someone who does. I don't want to wire a switch directly to the fan. I thought my problem was in the area of my wiring harness as is in these two pics. It wasn't. _______________________________
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:hello: Today I found color code discrepancies between the ZL 1000 wiring diagram, the fan cicuit explained diagram and the wiring harness on my ZL 10. :cussing:. All three are different. So the first time I ohmed out the wiring I must of not done it correctly. I'm not sure why I didn't see this before.
 
:hello: Yesterday I found a wire that has 10.5 ohms of resistance in my wiring harness. Today I'm going to undo all of the wiring harnes wrapping tape and replace the whole wire. :banghead:. :pain10:. :cussing:.
 
:hello: Anyone know which one of these (pic. 1 or pic. 2) is the engine oil temp switch 120*C/248*F. I have an OEM one that is marked oil pressure switch part # 27010-1313 which is in pic #2. The wire lead on it is a black wire with a red stripe. The one in pic #1 I can't tell what color the wire lead is.20230505_145937[1].jpg 20230505_150521[1].jpg 20230505_151209[1].jpg
 
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