ZZR 600 D1 where my spark gone?

leener · L Plate Warrior Joined: 05 Apr 2017 Karma :

Hi all.
Yes, I'm new here and not posted on any forum in years. Used to use gbbikers about a decade ago, and visor down, but after been off bikes for years, I'm back.

It'll be nice to meet some of you guys, and hopefully you do meet up have a few rides out. I'm looking forward to it.

So, before I can jump in and be a real bike again, I have a zzr600d that is old as boots and needs work. I have given it a quick paint, got an engine in, did oil and filter, new plugs, replaced coils, leads, rear wheel and various bits, and it ran. I even cleaned out the disgusting carbs. It ran great, except the slight issue of randomly cutting out in the odd occasion. It's definitely electrical. The side stand switch isn't the issue. I took it for a quick run this morning and it died around the block.

The tank is off and the Volt meter is on it. The thing is getting fuel, the fuses are OK, the solenoid is reading around 12v, the leads were a tad crap, so replaced a couple to get around 5 ohms each, the coils are getting plenty of power but not thoroughly tested then yet (too much pain), and there's definitely no spark (I did the test).

When I feel up to it I am going to try and get some response from the coils, but running out of patience with this thing.

Anyone want to add their two pence?

I'm up in Mangotsfield, Bristol if anyone is around fancy popping round for a cuppa in the week.
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Isj0321 · Two Stroke Sniffer Joined: 04 Apr 2017 Karma :

Sounds like a loose/bad connection somewhere.
Power getting to ignition?
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Raffles · World Chat Champion Joined: 14 Apr 2009 Karma :

dydey90 · World Chat Champion Joined: 01 Oct 2013 Karma :

leener · L Plate Warrior Joined: 05 Apr 2017 Karma :

Cheers, guys.

I'll try another new plug later even though I have new ones in there, but they're a bit fouled up already. (I only used half a tank with them). The coils seem to be OK but these are difficult to test for some reason.
Ignition is absolutely fine, tried that first thing. No wiring problem.
Pickup coil is another one to check.
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leener · L Plate Warrior Joined: 05 Apr 2017 Karma :

Well, I have had some fun with this bike...

Trying to do the while feeling like death is not that easy, but I enjoy it, so I will persevere.

Ignition switch is fine
Ignition coils seem fine
Ht leads are ok
Spark plugs not great but should still spark (5ohms)
Pickup coil is fine
Rectifier is fine
Solenoid is fine
Which leaves me with one suspect... Mr CDI. I have no idea how anyone would test one without another bike, so I did a few checks, and the power pins show continuity... The rest of the pins are null, and one fluctuates badly and goes down to null. I am pretty much stuck here. I am getting another plug to make 100% sure that they aren't the issue, and then consider another CDI box, or open the tub and get my soldering iron out.
I'm no mechanic, but I think I'm on the right tracks. :crybaby:
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