year 2000 electrics on a 1991 bike???

[lubricantpixie]

just got a new loom and junction box to replace my old broken ones, plugged the whole lot in but i cant get any power to my lights, horn, starter or anything. just wondered if i would have to change the ic igniter if there is a difference between the years. i have checked the loom between the ignition switch and the junction box/ relays etc and thats fine plus the junction box is fully working. I am really stumped and would appreciate any advise.

Cheers,
Charlie

[RedexRobB]

does anything come on at all when you turn the igniton key? Have you checked the main, 30amp, fuse?

[jackdim]

The import and UK looms are slightly different, not sure what you've got and if that'd cause problems though.

I'm also from Bristol so if you needed to check out my ZXR4's for reference then you're more than welcome to come and have a look over them.

Ta,
Jack

[parby81]

the fuse boxes changed around 95, pre that they only had four fuses and after they had 7. Needless to say a lot of the wires are the wrong way round or not to the right bits if you just plug it all in. can easily be worked out by looking at the wiring diagrams in the manual. the l model manual has both sets there. If you get stumped and this is the problem i am sure i have all the wiring changes in the garage somewhere. mail me if needs be, hope your good with the solder!!!

[lubricantpixie]

cheers for the replys,

i will check the main fuse tomorow as there is nothing power wise. hopefully its as easy as a blown fuse. otherwise it might be a problem with the wiring to the junction box, muddled wires etc. will have a look at it tommorrow then report back

Cheers,
Charlie

[bendog66]

it is the junction box as i had the exact same problem, although everything else plugged in fine to what was already there

[lubricantpixie]

junction box?

please elaborate, mixed wires?

[parby81]

What junction\fuse box do you have on the bike? How many fuses are there in it. As said it was changed in '95 and the wires for certain things differ in which connection they go into between early and late ones, although it uses the same connector block, hence the confusion.

W = WHITE_______________R/G = RED/GREEN
W/B = WHITE/BLACK_______R/W = RED/WHITE
BL = BLUE .ETC ETC
BR = BROWN

Power block 4 x 2 block connector

pre 95
W/B_____W_______BL________BR
R/G_____Blank_____Blank_____R/W

post 95
W______W/B_______BR_________BL
R/G_____Blank_____Turn Relay___R/W

As can be seen some of the wires need swapping around in the connection block and the power for the turn relay needs adding (see below)

Selection block 5 x 2 Block connector

Pre 95
B/R_________Y/G_____Y/R____BLANK_____BLANK
Light Green___BLANK__BLANK___G/B_______G/W

Post 95
B/R______Y/G________Y/R_________Light Green_____G/W
BLANK____G/B______Ignition Fuse___Turn Relay______Horn

So swap th elight green and G/W wires in to the two blank slots on the top and move the G/B along to the 2nd slot on the bottom row. Solder a wire from the brown wire on the IC Igniter to the middle of the bottom row. Snip the brown wire on the existing turn relay and soldering a piece of wire to both ends, run one end to the power block and the other to the selection block in the appropriate slots. Run an additional wire from the selection block to the horn and connect to the +ve side taping up the old +ve to the horn.

All complete and will now all work and pretty much everything on the bike is fuse except anything running of the White wire in the power block as this is the permanent live. If you don't know what you are doing wwith the electrics then leave it alone, but I hope this is of some help.

[parby81]

This gives you an idea of what you need to do. I was changing the early fuse box to a late one and this was what i needed to do to get it all to work. obviously you are changing the loom over not the fuse box so it may take a little bit of time to sort which wires need to go where, but this can all be done from the manual looking at the two pictures. Of course you could just buy the later 7fuse junction box that goes with the later style wiring loom and the wires should all be correct then.

Hope that all helps

Martin

[lubricantpixie]

cheers for the help, i have got a 2000 fuse box and the 2000 loom so would have thought they would be compatible but will have a look at the wiring

[lubricantpixie]

fixed it now.

thanks for all the help. had a problem with a couple of fuses that had blown and some mixed up wires. all good and working now.

Cheers charlie

[parby81]

no worries mate, glad you got it all sorted