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Project FZR fix up

Discussion in 'Your 250cc Projects' started by Yetiburger, Oct 7, 2017.

  1. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    So nothing changed when you swapped the other coil in?

    Did you swap the wire's around on that coil?
    The 12v should only go to the one side of the coil, if you reverse them i reckon the spark might be tiny at the plug
    A back fire through the carby's sound's like the Ignition coil's are plugged in to the harness the wrong way around and it's firing on the wrong stroke?
    Maybe try swapping them and see if it fire's ?



    Both the coil's run off the same 12v coming from the TCI,
    one of the 12v wire's to the coil's is tapped off the 12v feed from the first coil where it come's from the TCI, guessing the join would be near the airbox area
    If only one of the coil's is getting 12v then there must be a break in the wire or corrosion on the joint under the insulation, you've checked the terminal's are ok in the plug / socket where the coil wiring meet's the main harness ?
    Also look for sign's of corrosion where the coil wire's are crimped into the terminal's on both end's of the coil wiring, and same at the other end of the main harness where it plug's into the TCI.
    You can remove the terminal's from the plug's / socket's with a small flat head jeweller's screwdriver if you push the retainer tab down a little (push the wire/terminal into the plug / socket at the same time as you push the locking tab)
    If there's any corrosion you should be able to trim the end of the wire back a bit to where there's no corrosion, strip the insulation back a bit and crimp a new terminal on then refit it into the plug or socket.
    If they are all good then push the retaining tab back out a bit so it'll lock back into the plug / socket, then refit the terminal into the plug or socket it came from (do 1 at a time so it goes back in the right position)

    Screen-Shot-2013-06-13-at-10.32.33-AM.png
    56220__36926.jpg 5950x1b__83941.1423164709.380.500.jpg


    If you find that the coil is getting 12v when the ignition is on ( killswitch turned on)
    Then it may be a problem with the earth wire from the TCI, or possibly the TCI itself as @Linkin mentioned.

    You could test the switching of the TCI if you ran a test lead off the positive side of the battery and put the tip of the test light on the Orange wire or Grey wire from the ignition coil depending on which coil you are testing.
    You should get a flash from the test light when the coil you're testing fire's (may only be faint as it'll happen very quick)
    Make sure the coil lead's are all connected to the spark plug's, and that the plug's are all fitted to the cylinder head when testing otherwise it'll put stress on the electric's inside the TCI.

    Let us know the testing result's and we can advise you from there.
     
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    Last edited: Jul 23, 2018
  2. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    ok so I tested voltage across both coils and got nothing but one is still trying to fire? if i test from the pink wire on the coil and earth the meter to the frame i get over 12v?
     
  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    My 3LN3 has a red wire w/white stripe that supply's 12.6v + to both coil's when the ignition is turned on,
    and yeah you have to measure each coil with the black probe (from your multimeter) touching an earth.
    Guess your wire could be faded or they just used pink on the 3LN1's ?
     
  4. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    oh yeah ok. may be faded but its solid. so does this mean the coils are good and there is a problem with the TCI? is the black wire a signal wire to tell the coil to discharge? The mechanic said he popped a fuse when he turned the handle bars full lock. there is a 15A fuse in the main fuse holder.
     
  5. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Did you try testing whether the TCI is firing or not like i mentioned in my post above, after the terminal picture's ?

    The black wire's from the ignition coil's, do they connect to an orange and a grey wire on the main harness ?
    If so then yeah, the TCI earth's them out to fire the ignition coil.

    The pink wire's i reckon they might connect to a red w/white stripe wire on the main harness too?
     
  6. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    so would i put the test light on + on battery and black wire from coil?
     
  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Yes, i reckon it'll work although i have never tried it in practice.
    It may get a reading through the multimeter too if the test light doesn't illuminate
     
    Last edited: Jul 24, 2018
  8. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    i'll get a test light tomorrow. i do have a timing light.
     
  9. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    This coils I sent you came off a running 3ln3 , I have the cdi for it and a zeal cdi if that is the problem
     
  10. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    ok so update as to where i'm at.

    I have have over 12v to both coils with ignition on.
    with ignition off and the test light connected to +ve of battery and -ve of coil the light illuminates.
    with ignition on and test light connected the same no light but dose flash as engine is turned over.

    with timing light connected to battery and over lead 1, no flash.

    am I just instantly destroying coils?
    resistance of coil was 3.9ohms in primary before i put it in, with meter resistance of 1.1ohms
     
  11. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Sound's like everything is working electrically, have you tried it with a splash of fuel down each carby throat?
     
  12. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    but its not setting off the timing light so its not sparking? is the coil dead? could there be something in the bike causing them to fail? can I pull the plug and check for spark?
     
  13. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    in the good news I got the caliper apart and got the bolt out of the hub, so rims and brakes are off to the powder coaters soon.
     
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  14. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Some timing light's don't work with wasted spark system's
     
  15. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Yeah if you remove a spark plug and connect it to the coil lead, make sure the metal thread's or the long electrode tab are earthed to the engine, if it's not earthed well it can damage the Ignition coil's or TCI
    Spark should be blue/white, if it's yellow/orange then there's a problem with you coil lead, spark plug cap or ignition coil or possibly the TCI
     
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  16. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    20180730_180818.jpg ok so i pulled the plugs to 1/4 held the thread of each against the engine head for an earth and no spark so tried the lead from no.2 on plug one. no spark. but it will spark a nice blue spark from the thread of the plug to the cylinder head(if there's a wee gap)? does that seem messed up to anyone? is there some kinda short in the plug? would a new set of plugs be the answer?
     
    Last edited: Jul 30, 2018
  17. ruckusman

    ruckusman Well-Known Member Premium Member Dirty Wheel Club

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    FYI cylinder head may not be a consistent earth - one of the bolts which holds the cam cover on will earth directly - but from the sound of it the carbon built up in your plugs may be shorting from centre electrode to the outer and jumping to the cylinder head from there
     
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  18. Wozza

    Wozza Active Member Premium Member Contributing Member

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    How wee a gap? if its the same as the plug gap then yeah try some new plugs..if way smaller you have issues further back up the line..
     
  19. Yetiburger

    Yetiburger Active Member Premium Member Contributing Member

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    yeah about the same as the plug gap. I'll try some new plugs. does anybody no the number for the plugs? ive been told cr8eix.
     
  20. Joker

    Joker Coming and going... Premium Member Contributing Member

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