Fuse Box Dissassembly - 1991 to 1994 model

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banner001
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My Bike: ZXR400 L4
Location: Nuneaton

Fuse Box Dissassembly - 1991 to 1994 model

Post by banner001 » Sat Jul 28, 2018 11:21 pm

The L5 onwards is similar, but it has a few more circuits, the L9 is more complex again. I think this has been done before...but i cant find it so apologies if its a duplicate.

Reason for doing this, im putting my bike back to mint condition and want to 1. get rid of the copper oxide corrosion properly and 2. make sure the internals are as good as the externals.

This is my pin arangement - also 1/3rd of these are redundant in the L4 so these will be removed and the holes plugged with sealant:
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First you remove the rubber damper, the cover and the fuses, then you drill out the 4 plastic plugs - only need to go in a few mm:
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You can then pop off the bottom and finally the top to reveal the components:
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Desolder all the pins holding the main connection block in:
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Finally you will want to desolder the relay and the 3 diodes:
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Clean the board, clean all of the plastics, clean the electrical connectors, change the diodes for new, and the relay if desired and solder it all back together, with sealant to hold it all together.

This is an example of a fusebox that i bought thats functional, and looked good from the outside...
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