Kawasaki Concours Forum
The C10, aka Kawasaki Concours - The Original => Accessories and Modifications - C10 => Topic started by: m in sc on October 15, 2020, 01:10:07 PM
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How i did mine. Got idea from another guy on cog, but figured id share it here. if you're handy with a soldering iron, this is a no brainer. can swap out a potentially bad relay side of road if need be (but these are rated high so will probably outlast bike) the typical aftermarket 5-wire 30a automotive relay used for driving lights and elec fans.
diagrams are here that i used.
http://web.ncf.ca/ag136/jBoxDiagnosis.htm (http://web.ncf.ca/ag136/jBoxDiagnosis.htm)
split box, take relays off old board. note where they went.
(http://www.2strokeworld.net/wp-content/uploads/99-concours/jboxmods/jbox-mod_06.jpg)
(http://www.2strokeworld.net/wp-content/uploads/99-concours/jboxmods/jbox-mod_03.jpg)
holes drilled and grommeted, wires pulled. 4 wires per relay. (+, -, switched 1 and switched 2)
(http://www.2strokeworld.net/wp-content/uploads/99-concours/jboxmods/jbox-mod_07.jpg)
(http://www.2strokeworld.net/wp-content/uploads/99-concours/jboxmods/jbox-mod_10.jpg)
small mount plate on inner fender under seat on LH side of bike. sealed bolt holes and tapped plate to m6. used shallow bolts to mount relays.
(http://www.2strokeworld.net/wp-content/uploads/99-concours/jboxmods/jbox-mod_09.jpg)
(http://www.2strokeworld.net/wp-content/uploads/99-concours/jboxmods/jbox-mod_11.jpg)
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I bought some replacement relays that are pin compatible with the originals and soldered those in.
I also reinforced the tracks on the circuit board with copper wire soldered along each track and looped once around each relay pin. Then sprayed it all with conformal spray and put it back in the original case.
That was 5 years ago and still going strong. 😁
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yup. have done that as well, works great too.
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Will consider this thanks for sharing