Junction Box - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
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post #1 of 54 (permalink) Old 12-06-2008, 07:15 PM Thread Starter
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Junction Box

There seams to be a problem with the OEM Kawa JB's, Mainly the relays keep failing....I am wondering if there is a company that makes an aftermarket JB or a way to keep them from failing.

I am working on making a new Fuse box and a Relay Board. Removal of the old JB would be required. The fuse box would go in it's place while the relay box would be located on the back side of the Bat Box. I should have this mod done by Christmas.
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post #2 of 54 (permalink) Old 12-06-2008, 07:27 PM
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I would be interested in that! Let me know how it is comming along

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post #3 of 54 (permalink) Old 12-07-2008, 02:55 AM Thread Starter
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Well Right now I am in the research stage of the project...I have found that in order to make my new JB and RB (Relay Box as I am going to call it) all parts totaled together is much less than the OEM JB off of eBay. The New JB will have 8 or 10 circuits compared to the 6 currently available. This will leave 2 to 4 open circuits for adding stuff like driving lights, a power outlet for a GPS or Cell Phone, or any other electrical accessory you can think of wanting to add. I am also going to incorporating in a Load Equalizer for LED turn signals.

The JB/RB will be a direct plug and play unit using the OEM connectors currently used. (just to find the connectors...grr...)

below is list of parts I plan on using
Fuse Block QTY1
40 Amp Relay QTY (amount of Fused circuits)

Relay Connector QTY same as Relays

Terminal Board QTY 1

Universal 4-Amp Load Equalizer QTY 1


I also found some really neat Fuses that I want to use
MINI FUSE-LIGHT WHEN BLOWN


**NEED SOME INFO*** does any one know what the specs for the Diodes inside the OEM JB are? I just realized that they are there for a reason and need to make sure that I have new ones to replace the old with...

Last edited by slimvulcanrider; 12-07-2008 at 04:56 PM. Reason: Added Quanities
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post #4 of 54 (permalink) Old 12-07-2008, 08:25 AM
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Shoot now I wish I had kept the old blown JB for you to play around with!

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post #5 of 54 (permalink) Old 12-07-2008, 01:35 PM Thread Starter
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HaHaHa...np man...I'll figure this thing out
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post #6 of 54 (permalink) Old 12-07-2008, 03:01 PM
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I am very interested in this project. Don't forget to make a list of parts.

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post #7 of 54 (permalink) Old 12-07-2008, 04:51 PM Thread Starter
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Already started on the parts list...the only parts I have not posted are the wires ,the OEM pigtail connectors and the box I am going to house the whole thing in.
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post #8 of 54 (permalink) Old 12-07-2008, 06:51 PM
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I'm not sure that it's the relays that blow, so much as that diode on the headlight circuit. That is a consistent problem - I bought some diodes at Radio Shack awhile ago, and then got frustrated with the whole idea of breaking into the jb and replacing a part that I could barely see (especially with my delicate soldering skills!). I'll see if I can find the info on the diode for you.

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post #9 of 54 (permalink) Old 12-07-2008, 09:54 PM Thread Starter
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Thanks Cindy....I am starting to wonder if the diodes inside some automotive relays would work?
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post #10 of 54 (permalink) Old 12-08-2008, 12:28 PM
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Just speculating, but I think any diode with high enough current and voltage rating will do. Though the battery voltage is 12V, the diode voltage rating should be hundreds of volts. If the current is below 1A, as it probably is, a 1N4005 should work fine.
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