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Old 10-31-2012, 10:55 PM   #1 (permalink)
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Default 05 zzr 600 engine in my 02 zx6r, no spark ?

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.

Thanks,

Blake
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Old 11-01-2012, 11:25 AM   #2 (permalink)
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how strong is the battery?? 7.5v is quite a drop.....fully charge the battery and see where that gets ya
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Old 11-01-2012, 11:31 AM   #3 (permalink)
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Quote:
Originally Posted by badassjake View Post
how strong is the battery?? 7.5v is quite a drop.....fully charge the battery and see where that gets ya

Hey Jake, Battery is brand new, picked it up yesterday before i started the install. I had the charger on it at 2 amps while working on it as well as i figured i might run into a bit of issues while trying to fire it up. Sounds like its turning over really strong/fast as well.

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Blake
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Old 11-01-2012, 01:32 PM   #4 (permalink)
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Not positive but you might not get a spark off the frame because its coated. Its not bare metal so that may be why. Not for sure if that's why. Figured I would just give my input

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Old 11-01-2012, 05:44 PM   #5 (permalink)
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hmmmm....
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Old 11-01-2012, 07:11 PM   #6 (permalink)
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Trace everything from the plugs on back. Something isn't hooked up. Under the tail fairing on the left side is a box mounted to the subframe. Is it plugged in? If not, there's your smoking gun.
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Old 11-01-2012, 08:36 PM   #7 (permalink)
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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
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Old 11-02-2012, 05:15 PM   #8 (permalink)
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I found a complete wire harness that came with my zzr engine in a spare parts box, I've had it in the garage for over a year and forgot all about it. Installed the harness last night and have a new minor issue, going to make a new post for future search purposes, thanks for the help guys.

Blake
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Old 11-07-2012, 02:18 PM   #9 (permalink)
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Still struggling with the spark issue after my harness change. I tested my stick coils as per factory manual and they are fine. Bike is in neutral, clutch and sidestand switch are jumped. When testing the voltage to the 6 pin connector to the coils, the red and black only read about 2 volts when cranking, then back to 0 when not cranking. The black wire to any of the 4 coil wires (ie white/red...white/green etc) reads 6 volts while cranking. Also i just noticed that if i unjump my sidestand switch i read those same voltages. What should the output cranking voltage be on those? I read something about an anti theft swtich or resistor, any info on that or suggestions?

Thanks,

Blake

Last edited by blakesgst; 11-07-2012 at 02:30 PM.
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Old 11-08-2012, 03:52 AM   #10 (permalink)
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I've never heard of an anti theft anything on these bikes. This is a weird situation you're in.

So you have both safety switches effectively out of the equation and the bike cranks without trouble. So the switches aren't giving you the problem. Maybe the ECU is bad or something. Are you using a ZZR ECU or the ZX6R one? I don't know if they're compatible/swappable or not. Like maybe they'll plug in but won't work due to different pin alignment in the plug or something. It sounds like the signal to fire the coils isn't getting there.
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