Making your own Junction Box? - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 13 (permalink) Old 07-04-2019, 08:14 PM Thread Starter
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Making your own Junction Box?

Hello all, I'm new to the site and am waiting to go get my bike from a generous gentleman who I did some work for a few weeks ago. He told me that it needed a battery and some carb work. But from what ive been reading about these bikes in also planning on doing electrical work.

Now ive been reading alot about problems with the JB and R/R and /or stator. But heres what im wondering, can a person make there own JB with bus bars and all metal fuses? Wouldnt this be better than regular fuses and help with the dissipation of heat? I got this idea because I had to rebuild a JB on a 2003 VW Jetta turbo that I use to have. The JB sat on top of the battery. And thats how that setup was. Plastic enclosure with thick metal busbars and all metal fuses, not the ones like inside your cars fuse box. Im attaching a pic of what I'm talking about. Just wonder if this would work better?
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post #2 of 13 (permalink) Old 07-04-2019, 08:53 PM
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You're on the right track. There's a thread here somewhere about building a JB, with pics if they haven't been disconnected.

The problem isn't so much about blowing fuses, but eliminating the solid state relays (bypassing is good), and of course the circuit board in the JB is known to cause problems. So a scratch built JB is not a bad idea at all if you can do it.

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post #3 of 13 (permalink) Old 07-04-2019, 11:41 PM Thread Starter
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Does anyone have a pic of the inside of the JB on these bikes? Also whats the total amperage of a stock electrical system? I'm going to do a lot of research into this. I'm hoping to figure out a way to get this done and it benefit everyone with this bike willing to do the mod.
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post #4 of 13 (permalink) Old 07-04-2019, 11:46 PM Thread Starter
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As you can see the setup for this JB is for the purpose of relays. This is just like any relay box under the hood of any car or truck, but this is the way the germans engineered this part instead of the solid state relays most used. So would just have to figure out the right amperage fuse link to run and how to set it up to run certain things.
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post #5 of 13 (permalink) Old 07-05-2019, 04:31 AM
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There's a link to the wiring diagram in my signature. The junction box schematic is included in that image file, including the fuses and their amperages. Post back if you run into any mysteries.

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post #6 of 13 (permalink) Old 07-05-2019, 04:12 PM
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Any idea about diode values? 15 amp forward?

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
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handicap mods:
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heel shifter
extended brake pedal
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post #7 of 13 (permalink) Old 07-05-2019, 08:37 PM
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post #8 of 13 (permalink) Old 07-06-2019, 09:29 AM
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Quote:
Originally Posted by Hench View Post
Any idea about diode values? 15 amp forward?
I think the diodes are mostly just for relay switching logic functions, i doubt they carry any serious power.

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post #9 of 13 (permalink) Old 07-06-2019, 10:13 AM
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Quote:
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I think the diodes are mostly just for relay switching logic functions, i doubt they carry any serious power.
I went back and looked at schematic of JB. You're right! Not needed for home-brew JB.

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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post #10 of 13 (permalink) Old 07-06-2019, 10:17 AM
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Here's the thread that replaced the junction box with a home brewed fix.
How to Truly Fix the Vulcan's Electrical Problems https://www.vn750.com/forum/19-electrical/90426-how-truly-fix-vulcans-electrical-problems.html
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