Kawasaki Z400 - Service manual > Relay Box

NOTE

The relay box [A] has relays and diodes. The relays and diodes can not be removed.

Relay Box Removal

NOTICE

Never drop the relay box especially on a hard surface.

Such a shock to the relay box can damage it.

• Remove: Battery Case Cover (see Battery Case Cover Removal in the Frame chapter)
• Disconnect the connectors [A] and remove the relay box [B].

Relay Box Installation

• Installation is the reverse of removal.
• Run the leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Relay Circuit Inspection

• Remove the relay box (see Relay Box Removal).
• Check conductivity of the following numbered terminals by connecting a tester and one 12 V battery to the relay box as shown (see Relay Box Internal Circuit in this section).

*If the tester does not read as specified, replace the relay box.

Relay Circuit Inspection (with the battery disconnected)

*: The actual reading varies with the tester used.

Relay Circuit Inspection (with the battery connected)

(+): Apply positive lead.

(-): Apply negative lead.

Diode Circuit Inspection

• Remove the relay box (see Relay Box Removal).
• Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit in this section).

Diode Circuit Inspection

*The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the relay box must be replaced

NOTE

The actual meter reading varies with the meter or tester used and the individual diodes, but generally speaking, the lower reading should be from zero to one half the scale.

Relay Box Internal Circuit

1. Headlight Circuit Relay
2.  ECU Main Relay
3. Fuel Pump Relay
4. Starter Circuit Relay
5. Radiator Fan Relay

Fuse

30 A Main Fuse Removal

• Remove: Battery Case Cover (see Battery Case Cover Removal in the Frame chapter) Bolt [A]

• Disconnect the connector.

  Remove: 30 A Main Fuse Cover [A] Pull out the main fuse [B] from the starter relay with a needle nose pliers.

Fuse Box Fuse Removal

• Remove: Left Side Cover (see Side Cover Removal in the Frame chapter)
• Unlock the hooks [A] to lift up the lids [B].

• Pull the sub fuses [A] straight out from the fuse box with a needle nose pliers.

Fuse Installation

*If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage

• Install the fuse box fuses on the original position as specified on the lid

Fuse Inspection

• Remove the fuse (see 30 A Main Fuse Removal or Fuse Box Fuse Removal).
• Inspect the fuse element.

*If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.

Housing [A] Fuse Element [B] Terminals [C] Blown Element [D]

NOTICE

When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause damage to wiring and components.

See also: