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

[prfixer]

Fairly sure your first black wire is the temp, other one is pressure

 

[R. J.]

Ok: Thanks.

 

[R. J.]

I talked with PAUL on the phone this morning. He helped me out. We walked threw the fan circuit double checking what I did. We found that the black wire lead (pics 11 & 12) in the square relay has 4.6 ohms of resistance going to the temp thremo switch (part # 27010-1173) black lead. His bike had 0 ohms on the same black wire lead. When shaking and twisting the connector for the square relay part # (27002-1055) the meter ohms reading jumps between 1.5 ohms to 7.5 ohms. I still need to locate the wire lead that had 17 ohms of resistance. Pics #s 1 & 2 is the connector that plugs into the large slot on the fuse box. Pics 3 & 4 is the smaller plug the goes to the small slot. Pics 5 & 6 is the plug that goes to the square relay. Pics 7 & 8 is the plug that goes to the round relay part # 27002-1054. Pics 9 & 10 is the oil temp thermo switch. Part # 27010-1173. ____________________________

 

[prfixer]

That black wire also has a connection behind the airbox before it goes into the main harness

 

[R. J.]

OK: Thanks PAUL. I'll look into it. I started at 5 AM this morning on how to go about installing the new black lead for the engine over temp 248*F switch. I ran the new lead from the square relay along side the ignition switch harness over top of the radiator down the left side of the radiator through the hole that the fan lead goes through. then under the radiator then over the bottom radiator hose to the oil temp switch. See pics. I now have zero ohms on the new lead. I had to remove the top of the radiator and the top radiator hose in order to route the new black wire lead.

 

[R. J.]

Yesterday I found that other wire that had 17 ohms of resistance. It was running to the license plate light. I extended the two wire leads by six inches and put on new male barrel plugs. I went ahead and ohmed out the rest of the main wiring harness. Today I'll button up all the componets and clean up the frame and motor. _____________________________________________________________________

 

[R. J.]

While my fan comes on for both circuits as they should but not at the specified temps. It is coming on 10* higher. Most likely somewhere inside the main wiring harness is a corroded return. I asked this question before. . Does anyone know or know someone which switch relay can have an external on and off switch wired in so that the fan circuitry will operate as it should but also use a manual switch. In another thread Jared from OH said that he wired in a manual switch but didn't say how he done it. GOLDDRAKUL might know. Does anyone have their phone numbers. I don't remember Jared's Users name. Throughout the wiring harness is several crimped wires inside. I might have bad/loose crimp or high resistance at a crimp.

 

[furchin]

Jared is Jarney on this site

 

[markus56]

I'm sending you both their numbers in a message.

 

[R. J.]

Thank's MARKUS. The 97*c and the 110*c thermo switches are new OEM so I dought that they both would be out ot tolerance at the same time. Next I'm going to ohm out all the grounds/returns. The bike runs really good so I dought if any electrical/electronic parts are causing any problems. The battery is only a few years old.

 

[R. J.]

RED 1: Here is my fan circuit thread. After you install the rebuilt water pump that I sold you it has all the enfo needed for fixing any problems that you may have.