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05 zzr engine install in my 02 zx6r, no spark

B

blakesgst

New member
Joined
Oct 24, 2009
Location
Grover Beach, CA
Moto(s)
R6, F3
Hey guys,

I picked up a zx6r for a project that needed a new engine. I installed a zzr 600 engine today and it appeared as far as wiring goes there was just one 7 wire plug (the 2002 had a 4 wire and a 3 wire plug separately) i had to splice. All my lights and gauges work, bike turns over but it appears I'm not getting any spark. Voltmeter to both coils shows 12v when the ignition is turned on, when i crank it over that drops down to 7.5ish but there doesn't appear to be any spark getting to the plugs. I pulled a plug out, stuck it into the #1 Wire boot and set it on the frame while cranking the bike over and am not seeing any spark at the plug. Any suggestions? Anyone around that has done the swap that can give me some tips? I'd rather not pick up a complete zzr harness just yet, seems like I'm close.

Battery is new, picked it up yesterday....

Thanks,

Blake
 
Last edited:
-voltage is too low. try jumping it off of a non-running car.
-check all your grounds. i had a similar issue with a former gsxr, turns out i didn't ground the ECU properly (at all) after redoing some wiring... i'm wondering if you did the 3/4>7 pin slice and dice right here.
-double check the splices you did and that the pinout is correct. one crossed up wire pair is all it takes.

i am not even remotely close to an electrical diagnostician, but the above are all things that have bitten me doing similar shenannegins.

good luck!
 
auntiebling said:
-voltage is too low. try jumping it off of a non-running car.
-check all your grounds. i had a similar issue with a former gsxr, turns out i didn't ground the ECU properly (at all) after redoing some wiring... i'm wondering if you did the 3/4>7 pin slice and dice right here.
-double check the splices you did and that the pinout is correct. one crossed up wire pair is all it takes.

i am not even remotely close to an electrical diagnostician, but the above are all things that have bitten me doing similar shenannegins.

good luck!
Click to expand...

Thanks for the reply, I just added the battery was new to my post as you were posting this but i realize that doesn't always mean much. The previous owner had hacked up the harness pretty bad and the bike wasn't running when i picked it up. I am also wondering if it is a ground situation, when i get home from work this afternoon i'll start tracking those down.

Blake
 
put the battery on a charger at least, see if it comes up to correct voltage. you want 13.xx at rest after it's sat an hour off the charger

also i just noticed 12v was at coils. what is it at the battery?
 
auntiebling said:
put the battery on a charger at least, see if it comes up to correct voltage. you want 13.xx at rest after it's sat an hour off the charger

also i just noticed 12v was at coils. what is it at the battery?
Click to expand...

I'm at work now but i want to say it was a bit over 12volts alone and 13.1 when i had the trickle/ 2amp charger on it. I put the charger on it at 2 amps while i was working on it as I have noticed in the past from doing things like this you can drain a battery pretty quick trying to get a bike fired up for the first time in a while :p

Blake
 
blakesgst said:
I'm at work now but i want to say it was a bit over 12volts alone and 13.1 when i had the trickle/ 2amp charger on it. I put the charger on it at 2 amps while i was working on it as I have noticed in the past from doing things like this you can drain a battery pretty quick trying to get a bike fired up for the first time in a while :p

Blake
Click to expand...

Both those voltages are way too low. You need battery at 13 or so after it has been charged and then taken off the charger for at least a half hour. 12 at the battery won't start any bike. 12.4 barely will. 13 with trickle says the battery is probably bad.
 
afm199 said:
Both those voltages are way too low. You need battery at 13 or so after it has been charged and then taken off the charger for at least a half hour. 12 at the battery won't start any bike. 12.4 barely will. 13 with trickle says the battery is probably bad.
Click to expand...


Thanks for the info, I'll put it on the charger tonight and keep an eye on it.

Blake
 
blakesgst said:
The previous owner had hacked up the harness pretty bad and the bike wasn't running when i picked it up.
Click to expand...

Ouch, a hacked up wiring harness can be tough to debug.
 
what voltages are you getting out of the ignition pick-up diode when you're cranking the bike?
 
Ok here's where i stand. Battery sat on the charger all day and is good to go. I get spark on 1 and 4 which is the same coil, but not 2 and 3/ that coil. So i tested both coils and they are good but here is where I'm stuck.....

If i take the black and red wire from the coil that fires 1 and 4(right side coil) and connect them to the left side coil, i get spark so its something to do with the green and red wire on the left coil. What is confusing me is both sets of wires show 12v with the ignition on, the only thing that changes is the set of wires that works drops to about 5.5 volts when cranking it over, the set of wires that doesn't work drops to 7.5 volts.

I don't understand the wiring diagram for the coils, it shows spark plugs and ignition coils together, any ideas?

Thanks,

Blake
 
I also have a zzr (zx600j)
They have individual stick coils / spark plug boots
Didja check the connection where the sub harness to the coils plugs in to the main harness?
 
GPzPop said:
I also have a zzr (zx600j)
They have individual stick coils / spark plug boots
Didja check the connection where the sub harness to the coils plugs in to the main harness?
Click to expand...

I don't see any connections until all the way back at the ignitor box. If i unplug the left most connector on the ignitor box all 4 connections to the coils go dead, possible a bad ignitor?

Blake
 
blakesgst said:
Ok here's where i stand. Battery sat on the charger all day and is good to go. I get spark on 1 and 4 which is the same coil, but not 2 and 3/ that coil. So i tested both coils and they are good but here is where I'm stuck.....

If i take the black and red wire from the coil that fires 1 and 4(right side coil) and connect them to the left side coil, i get spark so its something to do with the green and red wire on the left coil. What is confusing me is both sets of wires show 12v with the ignition on, the only thing that changes is the set of wires that works drops to about 5.5 volts when cranking it over, the set of wires that doesn't work drops to 7.5 volts.

I don't understand the wiring diagram for the coils, it shows spark plugs and ignition coils together, any ideas?

Thanks,

Blake
Click to expand...

Define "good to go" on the battery. What exactly was the voltage after being off the charger for an hour. This is more important than you think.
 
afm199 said:
Define "good to go" on the battery. What exactly was the voltage after being off the charger for an hour. This is more important than you think.
Click to expand...

At work again but it was 13.5ish volts while i was working on it in the garage last night for the first couple of hours. I also had spark visible from 1 and 4 but not 2 or 3.

I have had this bike, engine and parts sitting for over a year and when i looked around a bit more last night i noticed i have a complete zzr 600 wiring harness/ignitor/junction box/stick coil set so i stayed up until the wee hours of the morning removing my hacked up harness and putting that one in. Everything is working except I've run into an issue with the start/kill switch control box. I can't seem to figure out which wires on the harness should be cranking the starter as the colors on the control box are different from the schematic and also I have been a bit confused tracing the wires on the harness in the schematic. 2 seem to activate the brake, 2 will turn on the fuel pump and 2 reds seem to do nothing so far.

Thanks for all the help so far guys,

Blake
 
I figured out my starter control box wiring and the starter/fuel pump are working great. After the harness swap and using a different set of stick coils I am stuck again with no spark. While the engine is cranking if i test the output voltage to each stick coil they are getting 6volts, is that correct? I'm getting mixed info through searching google, like stick coils will get 6 volts while standard will get 12. Also, battery is resting at 13.1 volts. I tested the stick coils as per the manual and they are in spec. Any ideas?

Blake
 
Just wanted to post an update in case someone has a similar issue in the future for search purposes. The problem was a small 100 ohm resistor in my ignition switch that had gone bad. Its part of an anti theft switch on my bike. After testing a gray wire on my ignitor box i was able to track it down. Picked up a new resistor, soldered it inline with that wire and the bike fired right up. More info here ...

http://www.ex-500.com/index.php?topic=38109.0

Blake
 
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