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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shocking

Im currently designing an L4 specific PCD board, if i can get them for a decent price ill order a few and sell them on here cost price...
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UK ZXR 400 L4
UK ZXR 400 L3 track bike
1989 FZR 1000 EXUP-R streetfighter

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banner001
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Posts: 2233
Joined: Sat Sep 24, 2011 3:27 pm
My Bike: ZXR400 L4
Location: Nuneaton

Re: Fuse Box Dissassembly - 1991 to 1994 model

Post by banner001 » Sun Jul 29, 2018 1:20 pm

Final finished design, needs to be printed so i can make absolutely sure that its correct, but from my testing so far its pretty much bang on.

Ill post up a price for the finalised item once i make them, now im off to Ebay for PCB's and ferric chloride...i already have a darkened oven, uv-photoemulsion and a UV exposure unit...

Image
UK ZXR 400 L4
UK ZXR 400 L3 track bike
1989 FZR 1000 EXUP-R streetfighter

User avatar
banner001
Track day God
Track day God
Posts: 2233
Joined: Sat Sep 24, 2011 3:27 pm
My Bike: ZXR400 L4
Location: Nuneaton

Re: Fuse Box Dissassembly - 1991 to 1994 model

Post by banner001 » Sun Aug 05, 2018 6:30 pm

I can now make PCB's at home :excited

First you make the positive, print it onto acetate, coat a silk screen with photoemulsion, place the acetate over the silkscreen when dry, expose to 1600W UV light bulb for 12 seconds, remove acetate was and dry...
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Pull ink through the screen and heat with a heat gun to harden...
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Heated ferric chloride and shaking removes the unwanted copper, then clean with isopropanol to remove the ink
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Trim, sand and drill locating holes...
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Need to wait for my tiny carbide bits to get here, then i can drill all the rest of the holes, ive fully cleaned all the plastic parts and the old copper pins, then solder and its good to go!
UK ZXR 400 L4
UK ZXR 400 L3 track bike
1989 FZR 1000 EXUP-R streetfighter

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banner001
Track day God
Track day God
Posts: 2233
Joined: Sat Sep 24, 2011 3:27 pm
My Bike: ZXR400 L4
Location: Nuneaton

Re: Fuse Box Dissassembly - 1991 to 1994 model

Post by banner001 » Sun Aug 05, 2018 6:36 pm

If anyone wants one of these boards ill sell the blank board (i.e. the second to last picture cut into 2 boards - absolutely no finishing done on my side!) for £7 (that's with p&p included), alternatively send my your fusebox and £50 and ill send it back to you in as near-brand new condition (i.e. refreshed copper pins, all clean, new board)

This is currently for the 1991-1994 zxr400 in UK-spec (so one pin extra for the headlight relay), i currently have no plans to do this for the <1991 or >1994 bikes unless demand is massive...
UK ZXR 400 L4
UK ZXR 400 L3 track bike
1989 FZR 1000 EXUP-R streetfighter

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