Zxr400 wiring problem

[Celticdan]

Hello I'm having a small issue with my zxr400 L1. The wiring loom to  
the fuel pump relay has come out of the plug and I no longer no what  
wire goes where I was wondering if anyone could tell me or email me a  
picture of the wiring configeration into the plug as I can't  work it  
out from the wiring diagram. Any help would be very appreciated.
Cheers dan.

[Daniel.p]

at the main page there is a workshop manual for the zxr-l the wiring diagram is there buddy

[Tirpitz]

I think he's saying that the wiring diagram isn't helping he him, he already has one, and he wants a photo of a wired up plug to work from. I have my bike in a partly naked state right now. If I can locate the relay when I get home I'll photograph it for you.

[Tirpitz]

Here you go mate

[Celticdan]

thanx tirpitz for the reply. the only problem is that i have 4 wires going into the plug. a red wire,black wire,black with a blue trace and a yellow with red trace if my memory serves me correctly.im new to all this.. i think this is a import as it had a kph clock set on it,im not sure if this would make any difference......

[Tirpitz]

Oh bugger, sorry mate I've photographed the starter motor relay :wanker

Be back in a bit if I can find the right relay for you.

[Tirpitz]

Right, this should be the right one. The relay is on the LH side of the bike, furthest one towards the rear - yes?

[Celticdan]

Thanx pal that the one. You saved my life.
I can now get the old girl running again.
Thanx again. The forum has been a great source
of information.

[Tirpitz]

No probs, glad to help

Don't run away now you've found us, let us know how you get on

[less_like_you]

Hey Hey

I too have some kind of wiring/electrical problem and I don't like it, I can do camchains headgaskets valves and timing etc, But never tinkered with my bikes electrics, Other than changing front headlight bulbs.

Really need some help with this, I asked a couple of people and they couldn't help me... Then i called cradleys. To ask a bit of advice.

I was in the fast lane of the m40 doing about 120mphish, When the bike lost all power, engine, lights, clocks the lot. I had to use my arm to signal me into the slow lane, I tell ya it was NOT nice!

Well anyway, hadn't a clue what had happened had to get my friend to pick me and the bike up in his renault family wagon as i call em. Suprisingly the bike fitted

Got it home and left it for a few days as i was annoyed and wanted a clear head to start fixing her, everytime i try and put the lights on or if the fan comes on, it all cuts out completely when a surge of power is used. It starts up fine, the battery starts it no problem. What cradley said is that the ecu needs 10volts minimum otherwise it cuts out and will turn everything off... Like it had been doing.

Cradleys kawasaki also said that its a fault with my charging system and its not charging properly, It could apparently be one of three things, The alternator, The regulator, or the rectifier.

One thing i forgot to mension to cradleys was that when i have the engine on or off but the lights off if i press the pass light switch to put the lights on full beam the full beam relay makes a buzzing noise and it shorts out, but it doesnt make a difference whether or not it is plugged in, the bike still cuts out when you put main beam on... Or if the fan kicks in etc... I am conifdent it has nothing to do with the lights themselves and it is most likely one of the three things mensioned, Just wanted to add that the relay makes that funny buzzing noise and cuts out the whole of the bike as well. But unplugging it makes no difference, Wondering why it makes the buzzing noise?? :S Due to lack of power maybe?

Whether i rev the bike to 8 or 10k it still cuts out. Thought that would be helpful to mension.

Sorry this message is a mess and i have repeated myself a few times in places.

Need some help fully establishing and eliminating the problem, As i have no idea what the regulator or rectifier looks like. I would prefer it to be one of those 2 rather than rip part of the the engine apart again.

Any help is hugely appreciated.

[RedexRobB]

I had a similar problem with another bike, and the wiring for the recitifier was corroded and came off. When i was riding down the road one day when this happened, indicated to turn off and the engine cut out and came back in sync witht he indicator flashing on and off.

Knowing these bikes as long as i have is most likely the rectifier. If you have a multimeter, check the voltage across the battery terminals witht he engine running, you should see iirc about 14.4V or so. The test for this is in the manual on the main page of ZXR world.

[less_like_you]

Thanks RedexRobB this will be the second time you have helped me fix my bike lol

Will borrow my friends multimeter as soon as i can and check out the manual.

[less_like_you]

Right ok, I cannot get hold of a multimeter, But i am pressuming that it is the Rectifier/Regulator, I found one on ebay, for £20.00 from a kawasaki spares place, rang him up and asked him if the part comes with a warrenty or garentee of some kind, and he said he can garentee that it was working when it came off of one of the zxr400s they had in and got put in to the spare parts bin, But i need to be sure that its the Rectifier and not the stator that is the problem as he sells loads of stators when people are claiming the rectifier is the problem when its not its in actual fact the stator. Guy seemed a little, hmm how should i say, Unhelpful, and slightly arrogant with the way he spoke to me, I have decent knowledge but don't know everything. Like i said before, haven't touched electrical systems on bikes before...

Can anyone give me some advice, I just want my bike repair asap, with minimal spending and minimal hassle.

[Tirpitz]

If you're going to do any electrical fault finding you're going to have to buy a multimeter if you can't borrow one. You're talking about £7 for one off Ebay http://cgi.ebay.co.uk/DIGITAL-LCD-MULTI ... 5adef06ea6. Once bought you've got it for life, it's just a handy tool to have. If you try to sort this problem without it it's just Russian roulette - you could strike lucky with the first thing you change, on the other hand you could waste £50 replacing perfectly functional components and still have a knackered bike

[Celticdan]

hello tirpitz. thanks for helping out with my wiring dilema the other day.i havent posted since i got the picture as ive been away on holiday.ive since put the plug back onto the fuel pump relay tried to start it with no hint of starting,ive now relised that the points on the pump are welded together.first of all where is the cheapest place to buy a repair kit and secondly would a faulty relay have caused this problem? this is the second pump in 2 months and ive only started it up a few times!! ive noticed that there is a constant live to the pump when the ignition is turned on and when the starter button is pushed it pulses is this correct ? any info would be great.