hybrid 550 yics/kz550/03 ninja cafe project. spark issues

So I know what you are gonna want to say about this... pics pics pics,So my apologies and promises go out to all yall. PROBLEM IS ITS MY FIRST BIKE,WAS ALOT OF OTHER GUYS BIKES BEFORE ME i LIVE IN A REMOTE LOCATION AND CAN RARELY GET ONLINE! So what i have going is the coils off the kz550,tank from the kz,front end off the ninja. eventually wanna snag the monoshock rear end off the kz. However the problem I cannot solve, is the spark on cylinder1 and 4cylinders is nonexistent or intermittent.Does anyone have a harness diagram for the ignitor that makes sense?Specifically on a chopped minimal wiring frameup? Pickup coils lead to the small 4 prong or the large 6prong? Is there a major difference on the coils other than the mounts? How pertinent are the grounds on the coils?Can they share a jumper wire to the frame?The kz has nice new coils that worked,{on it} now no difference and I screwed up the stock xj ones, If anyone has a happymeal or big box stash of the diagrams I need I will not forget your kindness,I have 2 days in the city to acquire them and the parts I need,then back to my snowy little cabin in the woods. PLEASE HELP! :?:

 

Welcome to the site !!

I'd advise getting Yamaha XJ coils. They need to be the correct OHM.
They fire ungrounded (at least at idle)

Someone can post the "minimum xj wire harness??" soon

 

Re: hybrid 550 yics/kz550/03 ninja cafe project. spark issue

Minimum wiring diagram can be found here:

http://xjbikes.com/Forums/viewtopic/t=3 ... agram.html

 

Re: hybrid 550 yics/kz550/03 ninja cafe project. spark issue

I have got that minimum wire diagram memorized.I went back to the original ig.coils and ran ohm resistance checks,secondary was fine around 11k however the primary had zero.does that mean anything in particular? Is that a common trait of bad coils,it doesnt make sense to me that the 2-3 coil was firing fine, if both show no resistance on primary. I still haven't gotten a good schematic or explanation about the ignitor harness connectors, thats specific to a 550 seca. INCOMING FROM PICKUPS IS THE SIX WAY OR FOUR WAY,ANYONE GOT A GOOD COLOR PHOTO/TOP/BOTTOM SPECIFIC? thanks if you can help.I really bugged the guys in the chainsaw forums but man are they in love with my saw now, I am determined to succeed at all costs,except shop costs.

 

Ok, we're looking at the upper left portion of the diagram in Pic 1. The wires connecting the "pickup coil" to the "ignitor unit" go to the larger 6 prong side. The orange, gray & red/white wires connecting the "ignitor coils" to the "ignitor unit" go to the smaller 4 prong side. Black is ground. I have my coils grounded where they're mounted & this wire grounds the CDI unit.

Pic #1:


Its a little hard to see but the black, orange & gray wires coming off the larger, 6 prong side of the CDI as seen in the bottom plug in pic #2 are stock wires running to the "pickup coil" in the motor. On my bike there is no brown wire as show on the diagram in pic 3; only black, orange & gray. I think the other 2 prongs left open are for the neutral dummy light & oil pressure switches, but who knows.

Pic #2


Pic #3


The 4 prong connection on the CDI box has 4 wires; Black, Orange, Gray & Red/White that run to the coils as shown coming out the right side of the CDI Unit in pic 2. My wiring in pic 4 vs diagram shown in pic 3:

Black = Black = Ground
Red = Red/White = Power to Coils
Yellow = Orange = Spark to Coil
Green = Gray = Spark to Coil

Pic #4


Hope this helps!

 

Thanks for the clarification,attention to detail rocks! "You tha man ignacio." as my old boss used to say. I seemed to have fried my multimeter,and I'm now doing the project off grid with minimal solar powered lighting and facing such hurdles hampers my diagnosis/testing ability at times,(mostly at night in my "SPARE" time) if u know what i mean. Anyway I will print it out and add it to my reference folder, thanx for your ever precious time. you will dig the pics soon to be posted,once running, One other thing....? I ran the resistance check on the Ig. coil Primaries without power from the battery and yielded Zero resistance...Is that due to improper diagnosis protocol?...should I have my mocked up ignition switch on and power to the coils when performing that test?... THANX!

 

also what is the oreintation of the wiring as opposed to the stickered side of TCI. my connectors are gone and dont wanna make any "ASS"umptions. In pic 4 the black,red and yellow wires are on the top,(stickered sid of tci? thanx again.

 

You need to replace the terminals with insulated shielded terminals. If one happens to come loose and touches something, it could cause damage to electrical components or a fire. It would be best to get the original connector blocks, you could check with Chacal at XJ4ever (top right of the page).

 

Good point Orange&Black. These pics were taken during mockup so I didn't have to try remembering which wire color goes where when I rewire with vintage style cloth covered wires.

 

i do have the covered connectors now just that theyre broken and could go in upside down. so which is the top row?

 

In pic #2 the label is on the left, in pic #4 the label is on the top.

EDIT: Found this pic online, but it shows how the CDI is orientated in pic #4. Flip the pic 90 degreeg counter-clockwise to match pic #3

 

shucks I think i had a bad connection or ground loose internally on this unit was tryng to get it apart when.....SNAP..it came apart alright.man some lessons are expensive..whos gotta good deal on one of these magic bluelabeled boxes? I snapped the board right on the edge where connections come in.

 

eBay. But a GOOD deal will take some looking for; the going price is usually right in the $100.00 range.

The best way to find one cheap is to find a "partout" where the seller is selling a whole box of relays, etc., as a "lot" and doesn't realize the separate values of the stuff he has. I've seen this quite often, and for $25 you can pick up about $400 worth of electricals. (The self-cancelling module is worth more than a TCI.)

Just be sure the label matches yours; while TCI units from other bikes may work, the timing/advance curve may be different enough to matter.

 

http://www.ebay.com/itm/Yamaha-Maxim-XJ ... 48&vxp=mtr

found one for 68. saw it whilst browsing. dunno if it matters from the 550 to the 650 but the numbers are the same. back to flea bay... lol

 

Re: hybrid 550 yics/kz550/03 ninja cafe project. spark issue

dude, killer find i think he has it miscategorized.blue label means 550 i think

 

Bingo! 4U8=550, not 650; good catch. It's mis-listed big time.

 

Re: hybrid 550 yics/kz550/03 ninja cafe project. spark issue

I have a no spark issue also. One of the wires coming out igniter has a disconnect piece and I'm not sure where it goes. Can anyone help me with this?

 

Sorry had a few technical difficulties are you still curious? I got my bike back and went out for "first" rides again yesterday. 1 year in the tow yard,poor baby, they asked if she was a Buell?! gas and a battery charge was all she lacked and she started right up. Now i'm back on the job. cheers