ignition problem!! Need Help

[Monsterquads.com]

Hi guys!!! I know that your into Hondas but I have and ignition problem on a 95 Kawasaki
ZX600E and I have been trying to get it to work for about a year. ( along with serval shops).This engine is installed in a quad. Check out our web site (monsterquads.com)and you can see what we do. Briefly what I have is a signal from the pick up coil going in to the cdi box . Nothing going to the coils.
( I have the motorcycle harness installed and this was a car kit) I have power to the right leads and ground to the right leads. We have replaced the cdi box twice, coils once,
load tested the harness and replaced the fuse box.( it has some type of diode bank in it) Tested all grounds to frame and engine. I feel it's not being triggered. If someone wants to give it a try I'll send more information and a copy of the schematic. Thanks and I enjoy your board. Rich p.s. these are all oem parts.

[Monsterquads.com]

Hi guys!!! I know that your into Hondas but I have and ignition problem on a 95 Kawasaki
ZX600E and I have been trying to get it to work for about a year. ( along with serval shops).This engine is installed in a quad. Check out our web site (monsterquads.com)and you can see what we do. Briefly what I have is a signal from the pick up coil going in to the cdi box . Nothing going to the coils.
( I have the motorcycle harness installed and this was a car kit) I have power to the right leads and ground to the right leads. We have replaced the cdi box twice, coils once,
load tested the harness and replaced the fuse box.( it has some type of diode bank in it) Tested all grounds to frame and engine. I feel it's not being triggered. If someone wants to give it a try I'll send more information and a copy of the schematic. Thanks and I enjoy your board. Rich p.s. these are all oem parts.

[Dan Deussen @ Weber Motor]

Look at the wiring diagram in the service manual. Most likely there are two wires from the CDI going to the ignition switch. One of them is the normal switched power and the other one looks like the same thing but it is not!!! One of those wires is most likely an anti theft device and the CDI will not work when put directly to power (or ground - I don't perfectly remember....try ground first, should be safe), instead it will require an inline resistor, which was 100 Ohms for our Suzuki GSX-R 600. I would imagine the same is true for your engine.

If you want you can send me the wiring diagram to dsdeusse@yahoo.com and I will take a look at it and maybe figure out which wire it could be.

[Mechanicaldan]

Ditto. You are missing a 150 ohm anti-theft resistor that is hidden in the stock wiring harness. (So 100 ohm, 150 ohm, something close?) It won't be on the wiring diagram in the factory service manual either. We have a 1998 Kawasaki ZX-6R engine. We had to add a resistor before it would start. You'll have to get a copy of the wiring diagram from a '98 Kawi ZX-6R service manual and compare it to the wiring on your bike. Maybe they are similar? Don't blame me if you short something out. Here's the instructions we were given for our '98 ZX-6R:

It's all on the Ignition system Circuit page, you just have to follow the white wire out from the battery to see some of it. Ground the Bk/Y wire to the neg side of the battery. Also ground the G/Bk wire to eliminate the safety switches. Put a 150 Ohm resistor on the same switch as the main ignition switch. The White from the battery goes into the switch, the wire coming out of the switch splits between the BR in the diagram and the Resistor to the GY. The GY goes into the ignition box as in the diagram. As the current goes through that switch and out the BR wire, it goes through 7 (Ign Fuse) and out as a BR/W. Then it splits with one going to the ignition box and one going to the 3 (Engine stop switch - Run position connects, stop position interrupts the connection). From the engine stop switch 3, it comes out as the R, then splits, one going as R into the Starter Button, and both R's going to each coil. The coils are grounded by the Ignition when they are told to fire. At the starter button, when the button is pushed voltage makes it to the BK/R wire. The Ignition box then sees that and allows the starter relay to turn the engine over, as long as the voltage coming to the GY wire is 6.5V. Wiring the Pickup coil and TPS sensors is self explanatory, just follow the diagram. The starter relay is all that is left. Just remember how relays work. When you allow current to flow through the activating coil, the other connection is made and the current is allowed to flow through the starter motor. A diagram is printed on the side of most relays. The starter circuit page shows how to connect the Bk/R to the Y/R of the starter relay. The BK/Y of the starter relay gets connected to ground. Everything else on that page has been bypassed or taken care of above. This should in theory run that engine. Just take care to label everything correctly, use soldered connections, used color coded wires, whatever, to make sure that if there are problems, it'll take much less time to diagnose. Just print this out and make your own wiring diagram.

Cyclone Racing
www.cyclone-racing.com/fhome.htm (http://www.cyclone-racing.com/fhome.htm)
Iowa State University
Engine Team Leader