No spark

[Shaun]

Hello there chaps

Let me tell you a story, its about a penny pinching young man who decided that to save a few bob he would drop out his engine and take that to a mechanic to have the head gasket changed then put the engine back in himself.

So, the lump went back in and everything was put back together and wires were connected, now I'm getting no spark from any of the leads. The battery sounds as though its gone a bit flat but when we put it into another ZXR it started first time with no problems so it can't be flat really. We have tried bumping it and that didn't work either.

I need to try and get it running tonight if I can, so I can go into wales and so Keith doesn't come round next week and find the problem in ten seconds making me feel silly.

I don't have any knowledge of electrics really so I have no idea where to start, suggestions please.

[stinkwheel]

Well, you have disturbed a few wires taking the engine out so I would check here first. Go over all the wires you had to disconnect when you took the engine out, make sure they are making good contact and are in the right place. Also make sure you haven't inadvertantly missed a frame earth connection by either not putting it back or bolting it to something that is rubber mounted.

Check your fuses. Including the main fuse that is often on the solenoid or the wire coming off the battery positive.

Coils? You maybe had to take them off to remove the engine. They making a good earth contact? Other connectors still attached?

What does work on the bike? Lights, neutral light, oil pressure light, horn, brake lights, starter motor?

EDIT: Sidestand switch? Connected and working or bypassed properly?
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Kickstart]

Hi

Basically you have a pickup on the crankshaft (or probably 2). Each set of coils will spark once for each turn of the crank. The pickups are probably on the end of the crank. Suspect the ZXR has the alternator up behind the cylinder with only the ignition on the end. As such the wires should be easy to find. Check these wires first.

If one coil was dodgy then you would get sparks on 2 leads but not on the other 2.

Kill switches on most Japanese bikes will stop the starter working as well, same for the side stand switch. You can probably count these out for now if the bike is turning over on the button.

Older ignition systems just worked the kill switch by earthing out the coils. However I suspect the ZXR works differently with a feed to the CDI. Worth looking for broken wires into the CDI.

Also worth checking for an "Ignition" fuse in the fuse box. Entirely possible that turning the ignition on with the battery connected but the wiring hanging around could blow this fuse.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Shaun]

Thanks for the help, looks like I've found the problem, I fitted new HT leads and coils because mine were shagged anyway, then I decided to check the main fuse, ya know, the one JP and Jay claimed they had already checked when that problem was suggested to me 2 weeks ago.



It should be a 30A fuse but a 40 was fitted and quite clearly broken, so I'm off to halfords to buy a fuse that isn't broken.

If you want something done right...

[Jrod]

Would that happen to be the fuse that I told you?

[Shaun]

That it would, last time I trust amateurs to be capable of checking a fuse.

[Jrod]

Get it to the dyno! I wanna see what kinda bhp it makes.

[Shaun]

Going to try bumping it in a minute, just got to wait until I can be arsed to push it up the street then run back down with it.

[Shaun]

Looks like I got all excited for no reason.

So, today I have replaced both coils and all HT leads, found that the main fuse had blown and replaced it, checked the wiring going into the CDI, all looks well and the kill switch and side stand switch are wired up correctly.

I don't know if the headlight works because its not plugged in but I know that the tail light and indicators work.

Oh I also replaced the reg/rec and have now checked it with both the old and new and I still don't get a spark.

Any more suggestions before I get annoyed and throw JP's tools down the garden?

[Shaun]

It lives

Found a rather dodgy connection in the end, queue runnign down the street bumping it, queue mike running along side the bike down the street with the throttle open in second gear.

Alls well that ends well, now it just needs putting back together a bit more.