After the finding the burn't fuse connector on my 2002 DF115 and running my "white wire" back to the battery isolator, I thought I would check all other connectors in the ECU box today.
What I found was 2 out of 3 rectifier connectors were well and truly burn't. I cut all connectors off and installed insulated crimps. By the looks of it the connectors have become this way due to loss of tension and one (the black connector) was actually welded internally. The male connector had actually slid up on top of the female connector.
Also one of the wires from the 30amp engine fuse is actually plain copper. As you can see it is totally corroded inside.
So if anyone is doing maintenance on their Zuke, it might pay to have a squiz at your connectors.
http://s1353.photobucket.com/user/ma...e%20connectors
Also replaced the 2200uF 25V capacitor ($2 at Jaycar) which is connected to the Grey wire. This capacitor helps keep the voltage up on the ECU whilst the engine is cranking. I tested the old one and it was down to 800uF. These electrolytics do dry out over time.
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