no spark from xj600 1987

I have just finished chopping the wiring up and with a lot of help from this forum and members i thank you, to the minimal to run, i have managed to get the bike turning over on the button woop...
i have tried to start the bike and nothing, so checked the spark and no spark from either ignition coil, i have checked different spark plugs so i think i can rule that out, checked the wire connectors on the ignition coil with a ohm meter and they are in the range in the wsm. the battery is fully charged.
i have bought some used igniton coils for another xj600 project which are a little different but i have hooked these up just to make suer and still nothing so i have put it back to how i had it and now when i hook the battery up it blows the 30 amp fuse instantly even with the ignition off i have blown 4 ....
any ideas ?
also just to check which order are the spark plugs ? sat on the bike from left to right do they go 1-2-3-4- or 4-3-2-1-?
thanks

 

left to right 1-2-3-4.

look in the areas you worked when changing coils in and out you could have pinched a wire.

 

this wouldnt affect the spark though would it?

 

what wouldnt affect spark ?
haveing plugs wired reversed no it woould still spark.
1 coil pack goes to 1 &4 the other coil pack goes to 2&3. it is also a wasted spark ignition so both plugs fire on the coil pack.

 

if the fuse blows with key off the wire that feeds the key switch may be pinched.
battery feeds the main fuse then goes to the ignition switch (key)

 

have you ohmed out the pickup coils

 

page 252 of fsm has a run down list for no spark / no start

 

hmm there was no blown fuse before the change over, and nothing more has been tampered with for it to be a pinched wire ...

 

yes i have checked the pick up and also in good order

 

You've got a short to ground/earth somewhere. You will need an Ohm meter. This may not be an easy task but you need to disconnect things one by one until it disappears.

 

How do you mean disconnect things , where would you start and how?

 

You've got something grounding where it shouldn't be. Got a wiring diagram? Time to chase down everything connected to the circuit that keeps blowing.

I can't remember what bikes were affected - does your bike have the glass tube fuses? Or blade type?

 

It had the glass ones but have been cut out and changed for mini blades, it's just the main 30amp that's blowing

 

So it's time to start unplugging stuff and start replugging. However, the one time I blew main fuses was because I had the sidestand and headlight relay backwards, but that was attributed to my poor labeling of stuff and lack of reading the Information Overload Hour. Ah to be young again.....

If you're having spark issues I'd start there - unplug the coils and see what happens.

 

So just buy a load of fuses and unplug stuff and see if it blows?

 

Unless you wanna unplug everything now and attach it one by one.

 

if fuse blows when you hook up the battery with key off disconnect the wires at the key switch.

 

Ah ok well I have no fuses left so will have to get some more and try this I will let you all know what happens

 

Hang on.... you said you're blowing fuses with the ignition off... do you mean the keyed switch is in the off position? Or the kill switch is in the off position?

 

Kill switch on .and key switch on and off when attaching the battery terminals it blows the fuses

 

Well, the problem is that it could be a lot of things. Something is grounding where it shouldn't be and is blowing fuses. Since it's doing it with and without main switch involvement, I'm thinking either a bad positive wire from the battery, or perhaps the switch itself.

Time to find a wiring diagram and see if anything else is between the positive terminal and the main switch.

 

remove wires to ignition (key)switch to see if the problem is the feed from main fuse to ignition switch.
if fuse does not blow remove all other fuses, reconnect ignition.
if main fuse blows look at what runs off of the blue wire and blue/red wire.
also may want to dissemble ignition switch and see if any wires are broken free.
brown wire feeds fuse block from switch
blue wires feed light switch and meter lights
blue/red wire feeds aux light and tail lights
these blue, blue/red wires are controled by main fuse

if main does not blow when all other fuses are out start replacing fuses.

 

It would seem likely that somewhere near the ignition coils that you were swapping out for troubleshooting that somehow a pinched / chafed wire is now present that supplies power to the ignition switch. Look at that area again just to be sure. Also a very good suggestion by XJ0550H to disconnect the ignition switch just to rule it out.

Also, don't forget the Rectifier / Regulator, as they are typically connected to the output side of the main fuse, so a defect there such as shorted diodes will cause the main fuse to blow.

Disconnect the Rect/Reg and the Ignition switch and if the fuse still blows it would pretty much be a certainty that the wire from the output of the main fuse is inadvertently tied to ground somewhere.

 

Ok so removed all fuses and ignition, put the main 30 amp in connected the battery and nothing blew, fit the ignition switch back in and all fine, fit all 3 fuses and again all good, so I'm not sure what the problem was, tried jiggling all wiring about but cannot get the fuse to blow again hmm I'm sure this will creep up on me again, but for now whoopee !

Also because I have removed the side stand switch and clearly not bypassed it properly this is what was stopping the spark so double whoopee !
Im sure there will be another hurdle to jump soon enough but hey for my first build I'm happy again thanks for the help happy riding

 

Newbie searching for my problem and this is it fsm?

 

Factory service manual FSM
which bike is it you have a problem with?
found your post.