www.zxrworld.co.uk

I’m having some trouble with wiring up my Zxr400 L5 race bike with a cut down loom. I’ve used the original full l model wiring diagram from the site and the h model race manual to make my own wiring diagram. I have made a loom with this diagram and I can’t get the bike to run. It turns over but won’t spark. I’ve removed the fuse box and starter safety circuit but want to keep the charging circuit. I need to know if I have wired the ic igniter correctly and if there is anything I have missed that is needed to make it run. The bike was running before I stripped the original loom. If anyone has any experience with making a race loom and can help me it would be greatly appreciated! I have attatched my diagram.

http://i19.photobucket.com/albums/b156/ ... celoom.jpg

Theres a resistor built into the ignition barrel of the L models to prevent hotwiring and it can be a bit of a pain in the face to bypass it - I have a H and have done a loom myself but I'm afraid I can't tell you where the resistor goes - its a 100Kohm AFAIK.

Sorry I can''t be of more help than that but it might set you on the path to enlightenment!

Cheers
Noel B.

fear ye nyou need a 100ohm minimum 0.25watt resistor. i'll check my wiring diagram and let you know where it goes. tomorrow night

please just advise. is it l or h model?

once i know that i can tell you for certain

ps don't worry i'm a zxr400 racer and an electronics engineer so wont bull you

my own wiring diagram is a bit shoddy (original with tippex and blue pen!)

i'm actually doing a new cad drawing next week for it which i could put in pdf format for you if you want a full race wiring diagram

don't forget to post it up here mate the more info the better!

Turns out i was given the wrong resistor from the tuning shop. I replaced it with a 100 ohm one from the tv repair shop and the bike fired up instantly. So my wiring diagram is correct after all!!!
http://i19.photobucket.com/albums/b156/ ... celoom.jpg

well done, glad you sorted it.

On the subject of 400 sp's can anyone out there post a photo of an sp igniter box showing the connectors and wires going in as i bought one recently for my bike and when it arrived some wires had pulled out of the connectors and i need a photo to see where they plug back in. Cheers.

I have just finished making a loom to the above diagram, and realised there is no circuits for the neutral light, oil light etc and no fan circuits

you dont need them anyhow do you? well maybee your oil light if your fussy

It's easy to wire in an oil, neutral light and fan if required. Just feed the lights with a live from the ignition and then the negative comes through the oil or neutral switches. As for the fan just feed it through the fan switch on the radiatior. I don't have a fan on my race bike.

I am about to make my loom next week after i order the stuff.
I just want to make sure this circuit works? i am crap at electrics, and find it hard to understand some of it!.
also i dont run a genny, so dont need the regulator. do i keep the wiring as diagram, just dont wire to them?
and what does the 'm' in a circle mean?
last, but not least.. can anybody recommend a supplier of wire and fasteners.
thanks!

This defo works.....I built my loom from it in March last year and it worked first time despite me being totally useless at electrics as well. The M is the live feed to the starter motor (the big thick high voltage cable).

Try these guys for your wire http://www.vehicle-wiring-products.eu/V ... mepage.php Very quick and efficient service and great quality wire at decent prices. Lots of colour choices and combinations too.

Good luck

excellent.
Thanks Alan

oh, also, i presume thinwall cable is the stuff? what gauge did you use mate?

I used thinwall on everything other than the higher voltage wiring e.g. to the starter button, fuel pump (I don't use a relay) and solenoid plus I think all my earth leads are standard thickness as well.

I'd build one for you, but it took me the best part of a day when I did it and you couldn't afford me