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

:hello: I know all too while how frustrating it can get when going into a problem when working on a bike & not knowing :banghead: if you are going about it the right way.
 
:hello: Guys a seller on E-Bay has all of the OEM discontinued switches NOS & relays NOS for the fan circuitry for sell. I bought one of each from him. He still has some. $28 to $49 depending on which one you buy & his prices are lower than anyone else. He bought out a closed KAW Dealer.
 
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:hello: Guys I got my NOS OEM cooling system relays & thremo switches in the mail today that I bought on E-bay. OEM Part # 27002-1055 large relay. OEM Part # 27002-1054 small relay. Both are located under right side of fuel tank. The box far right in the pic OEM Part # 27002-1052 is for another KAW. It comes with 3 relays molded in one rubber sleeve/hood. They have the same maker/manufacturer part # as part # 27002-1054. You get 3 for the price of one. I used a butter knife to remove the hoods to verify that they are the same. Oil pressure switch OEM Part # 27010-1313. Under right side of motor on the oil pan. OEM Part # 27002-1191 oil temp thermo switch. Front of thermo-stat housing which has red/white wire lead. OEM Part # 27010-1188 warning thermo switch. Rear of thermo-stat housing which has white/green wire lead. I'm still waiting on OEM Part # 27002-1180 thermo fan switch. Bottom rear of radiator with black wire lead. IMG_7166.JPG
 
You scored a lot of good stuff there R.J. but you must've cleaned him out cause I couldn't find any of it on his site when I looked.
 
:hello: I got my last 3 OEM NOS parts from that same seller said above. I didn't know that I ordered 2 of the large relays OEM part # 27002-1055. Shipped for $42 each. Thermo fan switch OEM part # 27010-1180. Shipped for $44. Spark plug cap OEM part # 21160-1065. Shipped for $32. Small relay OEM part # 27002-1054. Shipped for $44. Warning thermo switch OEM part # 27010-1188. Shipped for $28. Oil temp thermo switch OEM part # 27010-1191. Shipped for. $34. Oil pressure switch OEM part # 27010-1313. Shipped for $46. Non ZL 900/1000 Kawasaaki small relays 3 each no hoods. OEM part #27002-1052. Shipped for $48. This set of 3 are the same as OEM part # 27002-1054. IMG_7179.JPG
 
The first step in healing is idmiting you have a problem.
 
:hello: I just hate when I find parts after I order all new ones. :banghead:. Here is what I all have in stock. I recently seen some NOS fan circuit parts on E-bay cheaper than what I paid for mine. :pain10:. IMG_7419.JPG IMG_7420.JPG
 
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:hello: You can say that they are investments. :laughing7: Meaning sooner than later that they will all be obsolete from MR. KAW. :deadhorse. Most now are obsolete except for fan thremo switch black lead part # 27010-1180 (Price $88:cool: which goes on back center bottom of radiator. Large square relay (Price $46) which goes under the fuel tank located on right side of frame.
 
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:hello: I do not have any spare thermo oil temp switchs with the red wire lead. Part # 27010-1191 which goes on the front of the thermo stat housing. This part is no longer available from KAW.
 
:hello: The thermo over temp warning switch with green wire part # 27010-1188 location is on the rear of the thermo stat housing. It turns on the red light in the tachometer. It is no longer available from KAW. The thermo fan switch with black lead part # 27010-1180 turns on the fan. It is located at bottom rear center of the radiator. partzilla price is $82.
 
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:hello:Must correct you: the white/green cable switch (110°C) turns fan on when ign. ON, the red/white cable switch (120°C) turns on red led in tacho - big difference of both: 110 is a closer, 120 is an opener i.e. permanently on ground. The 120 is two times on the bike: front thermo housing and oil pan, only other connection plugs so when upper one fails you can 'switch the switch' w/ the downer one:laughing7:. Most riders I know pull off the oil pan switch cable so only 97°C in rad is working; when mine failed I wouldn't spend 80 bucks so I changed it for 1/2 price+some homework: https://www.zl-oa.com/community/threads/radiator-temp-switch-alternative-97°c.24724/#post-243614
 
:hello: I got my information from KAWASAKI parts fish. https://www.partzilla.com/catalog/k...-eliminator-zl1000-a1/radiator-fan-water-pump Fan switch 27010-1180 black lead. https://www.partzilla.com/product/kawasaki/27010-1180?ref=c4069a80a23227b131ab384b74e7ed758d54428eWarning switch 27010-1188 green lead. https://www.partzilla.com/product/kawasaki/27010-1188?ref=c4069a80a23227b131ab384b74e7ed758d54428e Oil temp switch 27010-1191 red lead. https://www.partzilla.com/product/kawasaki/27010-1191?ref=c4069a80a23227b131ab384b74e7ed758d54428e I must of got the packaging mixed up when taking pics of all my parts. As far as the location goes on the thermo-stat housing which on goes where.
 
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:hello: Location for thermostat housing thermo switches is on page 1 post 7 of this thread. Here is the correct parts (pic #1) with the correct packaging along with the location diagram parts fich (pic #2)and schematic (pic #3 & 4). which were taken from the ZL 900/1000 Service Manual Supplement. IMG_7647.JPG IMG_7645.JPG IMG_7639.JPG IMG_7640.JPG
 
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