Electrical issues

Tarmacsurfer · World Chat Champion Joined: 29 Jun 2004 Karma :

The ZZR died on the way back from Wales on Sunday. Engine would spin on the starter, but she wasn't even trying to catch, everything else seemed fine (lights, console etc) so I put it down to a dodgy connector.
Called the AA, got the bike home and into the garage and then just plugged the optimate in and left it. I have a fairly heavy chest infection at the moment, so been feeling too ropy to really get down and strip everything before now.
Went into the garage earlier, unplugged the optimate and turned the engine over on a whim. Off she goes on the first push of the starter.

Basically, does anyone have any recommendations as to good places to start the hunt for an intermittent electrical like this on a ZZR? I'm something of an electrical newbie, last time I had anything to do with the wiring on a bike I fried my GPz, so approaching this with alot of caution Confused

____________________
I'm immortal. Well, so far.

Demonic69 · The Pink Rhino Joined: 31 May 2002 Karma :

Could be the regulator/rectifier not charging the battery.
____________________
Back on a Blade. Just feels so right.

dibbster · Nearly there... Joined: 15 Apr 2004 Karma :

How old is the battery? and the bike?

I woul agree with Demonic that the rectifier unit would be a good place to start grab a copy of the wiring diagram and it should be easy to test whether or not it is functioning.
____________________
Suzuki RF 600 - The two wheeled Testarossa (Deceased)
Suzuki GSXR - Now stops on a sixpence; SBK3's Thumbs Up

www.bikepics.com/members/dibbster

Tarmacsurfer · World Chat Champion Joined: 29 Jun 2004 Karma :

ZZR1100 C, 1991 vintage. Battery is around 4 months old, a quick fettle with the multi meter confirms it's not the rectifier. The cut out was sudden, almost along the lines of the ignition system dying.
It's going to be a case of stripping and checking all the block connectors I think, it's most likely a corroded joint somewhere between the igniter box and the coils.
____________________
I'm immortal. Well, so far.

Big Pete · Spanner Monkey Joined: 18 Jul 2004 Karma :

if the engine spins over fine then theres no problem with the battery, its going to be in the ignition circuitry. Likely places are -

sidestand cut out corroded
kill switch shorting to earth
broken /corroded power feed to ignitor unit
internal contact problem at the main igntion switch ( but less likely as other stuff works)
corrosion/arcing damage in the fuse box
Fuse failing due to vibration - this ones a real bastard because the element cracks through and you cant see it, but it is an unreliable contact, particularily under load.

last but not least do you have an alarm with ignition cutout? if so check all the connections into the main Kwak loom, if there are the blue plastic connectors, remove them and do the job properly because they are the work of the devil Mad

good luck mate, intermittent electrical faults can be a pain to find. Thumbs Up

____________________
Trust me, I`m an engineer
GarageOfPower.co.uk

Tarmacsurfer · World Chat Champion Joined: 29 Jun 2004 Karma :

Just replaced the main ignition switch, the day before the barbeque in fact Wink

Side stand cut out is long gone, but I'll check the bypass.
Kill switch shorting, possible. The switch gear on these is prone to wearing, start buttons particularly.
Fuse box may well be worth checking, they've not been touched in a while. Given the problem seems to occur once the bikes warm then it's a possible.
Meh. I hate intermittents. Broke is fixable, but tracing something like this is a nightmare Confused

____________________
I'm immortal. Well, so far.