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Discussion Starter #1
Fellow Riders:

Concours 2001, ZG1000A16 .... Does J-box need rebuild or hot wire?

Is the problem a failed J-box or a wire becoming energized on its own. Heres the scenario...

Front directional lights and instrumentation lights go on after ignition turned off. This is an intermittent problem that only seems to occur after bike is very warm/hot after a long ride. When the lights do comeback on, it happens about 5 to 10 minutes after bike is switched off. when the lights come on on their own, the lights will go off when the ignition is switched On then Off. Already had to buy a new battery last week when the lights came on and i forgot to check them so they drained the battery beyond it being able to take a charge.

The ignition switch was replaced and problem still exists.

I think there is a wire intermittently being energized? There is only a small amount of wires exposed so before i start to tear open the wiring harnesses, do you have any suggestion?

In advance, Thank You
 

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You NEED a shop manual with a wiring diagram to see where that power really comes from......and things like, if there are any relays involved or not.

In general, things like that are caused by corroded fuse blocks or large connectors.
I think I'd start by pulling the fuse that normally feeds power to those lights. That would point the problem to a point before the fuse or after the fuse depending on whether or not they go out when in a "failing" condition.

What's a J-box ??
 

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Discussion Starter #3
the J-Box is the junction box where the fuses (and some relays) are located.

Thx for your assistance
 

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Discussion Starter #5
This is where I am at.....

I checked the wires around the jbox all looks good. I put the bike back together to let the problem re-occur. When the lights go back on by themselves after the ignition is turned off (after a 5 to 10 minute time delay), then I’ll tap the junction box to see what happens. From the Kawi forums I got a few replies saying to tap the jbox and even get more aggressive and hit it pretty good with the handle of a hammer. If the lights go off after the jbox is hit then they say the jbox is the culprit and needs replacement.

However, what I will do first is after I find the lights come on I’ll move around the exposed wiring harnesses under the fairing. If the lights go out or blink then I can continue to isolate what wire in what wire harness is at fault. If this has no effect, I’ll pull fuses at the jbox, one at a time, till the lights go out in order to isolate the circuit fault.

Last note is that I took the bike for a small run – 30 miles each direction. The lights did not come on from either ride. Won’t be back on the bike till either tomorrow night or Sunday so time will tell.

Really appreciate everyone's technical support.

~ David
 

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Have you gone over to the Concours Owners Group (COG) to ask your question? There are C10 experts over there who have seen it all and done it all. Those guys are modifying the C10 to keep it relevant in these modern times. Good luck.
 

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I had an issue on the C14 where the ACC relay would act up after I turned the key off. Looking at the wiring diagram, I thought it was the ignition getting wet. essentially, there is a ground provided by the ignition to energize the relay. In closing, I would inspect your wiring for pinched wires or chaffing where it can short (ground) to the frame.
Like Easy said, get a schematic so you can narrow down your searching to relevant wiring.

Here's a link to the site TWA was talking about. Wealth of knowledge there
Concours C10 / ZG1000 General Chat and Tech
 

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Discussion Starter #8
Update as I wait for the intermittent problem to reappear.....

The problem with the lights coming on on their own has not yet come to light (pardon the pun). The bike has been on quite a few rides with the longest around 150 miles. It is these longer rides when the bike seems to get really hot that the problem “sometimes” appears. All the other rides have been under 75 miles with no problems when it comes to the lighting situation (I do have a recent “mechanical” problem though).

It’s been a few weeks since I last communicated anything so I figured I would give an update. I plan on a few long trips in October so we’ll see what happens.

Thx for hanging in there with me.

~ David
 
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