ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

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banner001
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ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by banner001 » Mon Jan 27, 2014 5:47 pm

The L-model wiring diagram is a lot clearer than the H-model, but ive tried to make it even easier to follow by making a full colour version. Ive tried to make it foolproof to see where the wire joins are (big spots), the wires are coloured like this, solid colour wires are their respective colour, the pale green is the "light green" of the manual, white wires have a solid black outline, wires where there is a solid colour and a stripe are drawn as a solid colour and a dot - i.e. black wire with red stripe is shown as a black line with red dots on my diagrams.

I have all these as layered photoshop files so you can choose to just display certain wires, i have these for all 17 files here, PM me and ill send them to you.

I have kept my oil pressure light as it serves 2 functions:- firstly, i like to know that the oil is in my bike and not flooding out on track, and secondly the light will only be on if your bike's battery is connected and the bike is not running...prevents you from leaving it on there accidentally. If you wish to remove this simply remove the 2 wires at any stage of your wiring build.

Note: Change the 30A main fuse to a 10A

1. Full wiring diagram
Image

2. Remove horn, sidestand switch and neutral switch:
Image

3. Remove indicators front and back:
Image

4. Remove indicator dash light and turn signal relay:
Image

5. Remove headlights and city light:
Image

6. Remove licence plate light and rear/brake lights:
Image

7. Remove cooling fan and wires from fan switch:
Image

8. Remove headlight relay and wires to LHS:
Image

9. Remove remaining wires connecting to LHS and clutch lockout switch:
Image

10. Remove remaining headlight wires of RHS and neutral light:
Image
Last edited by banner001 on Tue Oct 17, 2017 9:38 pm, edited 5 times in total.
UK ZXR 400 L4
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by banner001 » Mon Jan 27, 2014 5:47 pm

11. Remove front and rear brake switches:
Image

12. Remove speedometer/high beam/water/tacho light and associated wiring:
Image

13. Remove ignition barrel, connect white to brown, and connect white to grey via 1W 100ohm resistor, remove 1 black wire from alternator:
Image

14. Remove the brown and white wires going to the fusebox, connect the green/black wire to any available black/yellow wire and join the black/red and yellow/red wires together - you can now remove the fusebox:
Image

After step 14 you have a standard race loom, this can be modified further:

15. Remove yellow/red and black wires from fuel pump relay, connect black/blue wire from fuel pump to red wire and ditch fuel pump relay:
Image

16. Remove alternator and reg/rec:
Image

17. Wire battery +ve end to 10A fuse and then to white wire, remove all others along with starter motor and starter relay:
Image

This completes the full race wiring loom. Obviously the loom can be made even smaller and more compact by shortening certain wires (i.e. connect the green/black and black/yellow of the IC ignitor earlier), by connecting the white "ignition" wire to grey and brown closer to the IC ignitor and so on...but this would require me to re-write the "stock" diagram, which is not the purpose of this post.
Last edited by banner001 on Sat Jul 29, 2017 7:20 pm, edited 1 time in total.
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by rmkd177 » Fri Feb 28, 2014 12:29 am

This is not correct. You are showing a permanent live to your cdi when the battery is connected. Although you can switch the ignition off your cdi and 9v 'anit theft' are permanently live, not a good practice. :smt018
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by banner001 » Fri Feb 28, 2014 10:51 am

in practice though there is no difference, on my loom you need to have the battery connected and the kill switch to run to fire the bike...on the race manual race loom you need to have the battery connected and the kill switch set to run...i dont see the difference.

as my bike is total loss i remove the battery every time so i can charge it, also doing it my way is the way to do it from a stock loom, requiring you to only make 3 changes from the stock loom, as opposed to the loom in the race manual which requires you to make many more wire connections...its a simple guide for those people who are unfamiliar with electrics.

what you meant to say was:
"This is not the way i would do it. You are showing a permanent live to your cdi when the battery is connected. Although you can switch the ignition off your cdi and 9v 'anit theft' are permanently live, not a good practice."

and as i mentioned before, i leave my wiring like this, and with the oil pressure light wired in as it provides me with an instantaneous way to check if the battery is connected and that my bike is "live", and doing it my way again means that you only need to make 3 connections that the original loom didnt have, everything else is a case of clipping wires -> easier.
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by cargo » Fri Feb 28, 2014 11:09 am

I had a CBR600 race bike that had a chopped loom.................it suffered a similiar problem that RMKD describes. If I left the battery connected for the journey home with the bike in the back of the van the battery would be near flat and incapable of starting the bike.
I wired in my own oil pressure light after I'd bought the bike as a road riding type at the time it brought me a level of reassurance

Leaving the CDI live is defo not good for it

Discharging the battery (when I forgot to disconnect ) reduces battery life.

The very hassle of disconnecting and reconnection the battery during a race meeting with 4 practice sessions and 4 races drove me nuts

And in the exciting aftermath of a race it was always easy to forget to disconnect

I just don't have those hassles now with my ZXRs and I charge the battery with it still in the bike via a little plug in connector on the bike.


Horses for courses I suppose

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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by Mori Man » Tue Mar 04, 2014 2:15 am

Instead of bickering about this how about a constructive post with a solution ?

OP doesn't want to add extra wires just snip so add a flip switch on offending wire.

Some racers don't want extra weight so snip offending wire and extend to kill switch.

Was that so difficult ?

MM!
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by Mori Man » Tue Mar 04, 2014 2:16 am

BTW , top work on the illustrations banner
Nothing worse than having an H and not being able to scratch it !
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by ross46 » Thu Mar 06, 2014 6:03 pm

well said MM, and well done banner, youve obviously put a lot of time and effort into doing this to help other people, i know that i will find it useful!

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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by banner001 » Fri Mar 07, 2014 9:08 am

cheers guys.
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by Aripug » Mon Jul 28, 2014 6:34 pm

Thanks for the illustration!!!!
Thanks a ton! I'll print it in A3 color and i'll put on garage!!! It will be helpful! :)=
:) "Your blood runs Lime Green , that's good enough for us" :) By Mori man

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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by spike » Wed Aug 13, 2014 5:03 pm

love the colour diagram!!!!!

thank you

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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by Paul RF » Mon Jan 26, 2015 10:18 am

This looks useful to me, will properly not leave anything live though, but fit flip switches in line.
All I need now is the time to do it geek

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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by Smokingviper1 » Thu Jul 25, 2019 9:22 pm

Amazing post, thanks banner for the time put in to it, this the same as the L5? I see no difference, trying to fix electric issues
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Re: ZXR 400 L1-L4 UK Full Colour Wiring + Race Loom Mods

Post by banner001 » Fri Jul 26, 2019 7:28 am

Smokingviper1 wrote:
Thu Jul 25, 2019 9:22 pm
Amazing post, thanks banner for the time put in to it, this the same as the L5? I see no difference, trying to fix electric issues
The L5 colour wiring diagram is available on this site if you need it, it's basically the same, but the junction box has fuses for more electrical circuits (7 as opposed to 4 on the earlier bikes), if you are having an electrical issue make a new post and let's see if we can fix it
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