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

[R. J.]

HARRIMINATOR: Thanks for strighting me out. .

 

[Marcel]

In addition:

Simple test to check if the relays are working:
You only need a 9V battery and a set of crocodile wires.

The relays are hanging on the front right side of the frame under the gas tank.
According to the Cooling System Wiring of the manual you can find the plus and minus (earth) wires. (Picture 1).
For the square relay (058700-0890) the plus is the Brown wire and minus is the Black wire (picture 3).
Take the plug out of the relay and remember the positions of the Brown and Black wires.
Add the Black crocodile clip to the pole on the relay where the Black wire was connected.
Add the Red crocodile clip to the pole on the relay where the Brown wire was connected. (Picture 4)
MAKE SURE THE CLIPS ARE INSULATED!!!
Add the other side of the Black crocodile clip to the Minus of the Battery. (Picture 5)
Touch with the other end of the Red crocodile wire the Plus of the Battery (picture 6).
You should hear the relay clicking which means it works and shifts from the 97C sensor to the 110C sensor.
This relay will ONLY work on your bike when the ignition is ON BUT also when your Oil Temp Sensor/Switch (120C) is still working!!! If this sensor/switch is broken the relay will never be activated!!

For the “round” relay (058700-0860) the plus wire is the White/Blue wire and the minus is the Yellow/Blue wire (see pictures)
Watch out: this relay has 2 White/Blue wires connected but the one for testing is the one besides the Yellow/Blue wire.
Testing works the same as the square one.
On the bike this relay will only start to work when the 97C sensor/switch is still working.

Hope this info helps.

 

[Ed]

The relay could be clicking normally but you should check for continuity at the switching side when it clicks. The contacts might be dirty inside so even though it clicks, it doesn't mean it's actually doing any switching and could still be bad.

 

[R. J.]

In other words just go ahead and replace both 30 + year old relays.

 

[Marcel]

When the relay clicks you can also test the left over poles with a Ohm meter by making contact with the pole and earth (for the square relay).
With the round relay just make contact between the 2 leftover poles.

 

[fstarocka]

Im gonna chime in and add some arrows to the pics RJ took (my phone card filled up yesterday while filming!)

Hope this adds some light as well -

 

[R. J.]

My fan on my ZL 1000 is getting rather noisy again. I've replaced it three times over the past 12 years or so with a used motor from a ZL9/10. At one point in time I installed a MUZZY aluminium fan onto the ZL10s fan motor along with the dampener that came with it. It has one extra blade over the stock one. It is a fan that I got off EBAY and is for the 1986-2006 CONNIE. It does circulate much more air over the stock fan plus the stock fan was brittle and the blades was starting to chip away. So I was wondering if a OEM fan from a CONNIE will work on the ZL9/10. I need just the motor. Does/can somone compare the two to see if they are a close match. ZL 9/10 fan assy. https://www.partzilla.com/product/kawasaki/59502-1061?ref=null . ZG 1000. https://www.partzilla.com/product/kawasaki/59502-1067?ref=null . I found this. https://www.ebay.com/b/Motorcycle-Fans-Fan-Parts-for-Kawasaki-Concours-1000/177963/bn_21788968 . They have many options. Connie fan motor only. https://www.ebay.com/itm/284043366073?fits=Model:Concours+1000|Make:Kawasaki&_trkparms=amclksrc=ITM&aid=1110006&algo=HOMESPLICE.SIM&ao=1&asc=248487&meid=c1fd0a9d524548f2aa46776fc20c46a4&pid=101195&rk=4&rkt=12&sd=383656782803&itm=284043366073&pmt=1&noa=0&pg=2047675&algv=SimplAMLv11WebTrimmedV3MskuWithCorrectedLambda85UpdatedPriceKnnRecallV1V4V6ItemNrtInQueryAndCassiniVisualRankerAndBertRecall&brand=Kawasaki&_trksid=p2047675.c101195.m1851&amdata=cksum:284043366073c1fd0a9d524548f2aa46776fc20c46a4|enc:AQAIAAABYCOUlUj%2FV4NxSoRpJlsxTSUOqt8qW2c%2BTIoltBcSXv%2FtgBRDMFb7GwGJR2Bnhzsx%2BbrLzH9oourCOVG6mOpO43Ufs8oPtLyGjYIInSD1BrVUTyJ6XwwkUEZCsmle%2FgEu3OsPjbTnOo7bs9LHNNohjga7os%2B4iA4R6P1WwQGp2o0QXeKfzOMI98eUN8KBUgWSw3C9hMmX%2Fa5mmkC95sJJqmM0%2B2KdNlros9LUbtugK2GvY682d5mPCM0YtizaFGZ%2FcB8F9b%2B4v6yFujS5IAIBFB34h%2FZRWU7HPUpPVBJeFQ7a9mwTgl5aTEMX9rQ3Ih5p9Ys4gmDbfzjMrX3b82XZJhlmXKvw%2B1RJqruH9Rauq4C7SRMjBwYE7Eu7sSvwv%2FTTCKfvilnQBEroMUhnv2n2awW6gd3o2EvVi61UaLXnMfGhKD5x2Pcg0mBdZLMIH3ZMa0%2FOnE9r07wGzUDvpmg38Io%3D|ampidL_CLK|clp:2047675&epid=1811835156 . From 2003 CONNIE. https://www.ebay.com/itm/383656782803?fits=Model:Concours+1000|Make:Kawasaki&epid=1811835156&hash=item5953b9ebd3:g:H8UAAOSwGGNfIvG3 . ZL9/10. https://www.ebay.com/itm/266193569339?_trkparms=amclksrc=ITM&aid=1110006&algo=HOMESPLICE.SIM&ao=1&asc=20200818142055&meid=bfc6e82c0394484aa387467942fadea6&pid=101111&rk=3&rkt=12&sd=371472297768&itm=266193569339&pmt=0&noa=1&pg=2047675&algv=DefaultOrganicWebV9BertRefreshRanker&brand=Kawasaki&_trksid=p2047675.c101111.m2109 . Found this CONNIE Forum. https://forum.concours.org/index.php?threads/muzzy-fans.22804/ .

 

[R. J.]

MUZZY FANS must of went out of business. I found this. http://www.oemcycle.com/Products/En...+Muzzys_Aluminum_Cooling_Fans/_Vid49458569e12 . I typed in several different bikes and all came back discontinued. Not sure about this web site. https://www.dragbike.com/muzzys-2008-hayabusa-aluminum-cooling-fans/ .

 

[R. J.]

Yesterday I test rode my ZL 1000. I think the cooling fan died. Now it doesn't come on at all. I done a quick check to make sure all the relays and switches was plugged in. Then I let the bike sit in the garage while running and let it heat up to 232* F. The fan still did not come on so I'm going to check all the fuses. Also my fuel gauge is not working. Since the fans motor bearing was really noisy I ordered a fan motor ($36 shipped) from a 2003 CONNIE off of EBAY. By looking at pics of a ZL 10 and a ZG 10 fan motor they have the same shape and mounting holes so I'm hoping the ZG fan motor will mount right up. I do know the fan blade is the same for both bikes because when I ordered the MUZZY aluminum 5 blade fan it was listed for a ZG 1000. The stock fan has only 4 blades.

 

[R. J.]

This afternoon I rode my bike and the fan is still not coming on at all and the fuel gauge still reads empty. So I drained the coolant and fuel. Pulled the fuel gauge float sending unit and checked the resistance of the built in variable resistor. I still have my notes from last time and the measurements are about the same. 104.6 ohms when set to the empty position and 2.1 ohms when set to the full position. I have about 2,800 miles or so on the coolant and it looks really good. No rust at all. My used CONNIE fan from EBAY should be here next Thursday. ____________________________

 

[prfixer]

Did you put 12v directly to the fan yet to rule out all the other possible causes?

 

[R. J.]

I'm going to do that this morning. Even if it does come on I'm still going to use the one from the 2003 CONNIE. When it did come on the bearing was really loud. As of now I'm on my 3 th ZL fan.

 

[R. J.]

While I removed the radiator and jumped it directly to the bikes battery. It works and now it is not making that bad noise I was hearing . . I'm still going to wait on the 2003 CONNIE fan I ordered from EBAY to make sure it is going to work for next time. I'm going to stand the radiator upright and test it again. ___________________________________________________________________________________

 

[R. J.]

Test #2 with the radiator standing upright as it would be on the bike. I let it run for 10 minutes. I have the muzzy fan blades on backwards. . The CONNIE fan has 4 blades and the MUZZY fan has 6 blades and not 5 as I stated earlier. Should I use the 2003 CONNIE fan motor or the ZLs?

 

[87kawzl]

I'd stick with the muzzy. It will pull better than the stock fan.

https://www.quora.com/Does-increasi...utted-airflow-If-so-how-in-regards-to-physics

 

[R. J.]

I'm talking about the fan motors and not the fans themselve. Should I use the stock fan motor or the one from the 2003 CONNIE, that is if it will work. The longer I run the stock motor the better it sounds. I am planning on using the MUZZY fan. I did not have the MUZZY fan on the motor backwards as stated earlier. It can only go on one way because it has a nipple/indent on the center of the fan blades. It goes over the shaft in the center of the fans motor. The shaft has a C-clip on the end. So I removed it thinking the bearing inside can be replaced. I put 2 screws in the fans mounting points. Then I put the motor face down in my vice on the heads of the 2 screws and tried to pull the aluminium housing out. I gave up on that. . The reason I thought the fan blades was on backwards is the fan blows on the bikes engine and not the radiator. I thought it was the other way around. ________________________________________________________________________________

 

[R. J.]

I hooked up alligator clips from the fan motor then reversed the polarity on the bikes battery as expected the fan rotated towards the radiator. I've never changed any wiring for the fan operation so from the factory the fan has always blowed on the motor and not the radiator??

 

[prfixer]

I’ve never thought about that but would ASSUME it would be trying to pull air through the radiator just as fans in our cars do. So yes, blowing air towards the motor would be what I would expect.

 

[R. J.]

I've Replaced the fan motor 3 times since 2012 and never questioned which direction the fan blows. Some air is directed towards the radiator because of how the housing is shaped when mounted in the radiator housing. Air does come out the front of the radiator but not as much as the rear. I'd say 70% of the air flow is towards the motor and 30% towards the radiator. I'd say the 6 blade MUZZY fan blows 25% more air than the stock 4 blade fan. I've been looking around the internet for someone who might have a MUZZY fan for the CONNIE in stock but have had no luck.

 

[R. J.]

While I got my 2003 CONNIE fan motor in the mail today. It runs but it hits the fan shroud on start up. The CONNIE fan motors shaft has play in it. So I'm sending it back. The bearing seems to be bad. I found out what was making that noise on the ZL fan motor. That green sound dampener was falling apart. . Nothing wrong with the ZL fan. While I was waiting on the CONNIE fan to come I cleaned up my radiator and put a few coats of flat black high heat paint on it. If anyone buys a CONNIE fan motor they are the same as the ZL 9/10. The only thing that would need to be done is to swap out the connetor and take the yellow wire off that is for the temp sensor switch and lace it in with the black and blue wire. ____________________