www.zxrworld.co.uk

One problem solved! I've discovered why the battery was charging intermittently.

The switched live between the ignition barrel and the Regulator Rectifier was showing an inconsistent resistance but letting through some power. I've soldered over the connection points in the ignition switch and it's now charging nicely. I'll be needing a new ignition switch if anyone has one as this is obviously only a temporary fix.

The problem is not quite solved yet. The bike is still stalling if I give it some revs then let off. The revs also hang before its stalling. If I connect the fuel pump directly to the battery it works and the bike will run faultlessly.

The pump does suck some fuel when I start it. My theory is that whatever controls the fuel pump is not telling it to pump more fuel when given revs. But what does that? The CDI?

Any theories and help welcome, you guys have been great so far.

AFAIK

the float valves in the carbs control the fuel pump, once the bowls are full, they close, preventing more fuel from entering, this in turn causes a pressure build up in the feed from the pump, which stops the pump.


seeing as it runs fine with the loom bypassed, could it be another dodgy connection in the loom somewhere ?

Any ideas where to look? Your right it must be something dodgy in the circuit.

My guess is the engine stop switch not making a good connection (unlikely given that the coils and pump work when using the starter switch) or the starter relay not supplying power through the yellow/red wire.

Edit - Or the CDI black wire (but again that supplies the coil)


Here's the circuit;

well, the black wire is also the signal feed for the tacho .. which you were also having problems with ? so i'd look there.

EDIT: maybe it does tell it to pump more when its being revved after all ?

Blimey that was a quick reply, cheers! Having looked at the full wiring diagram (I guess that's what you did) I agree. I'll see what I can do with it early tommorrow morning (If I get any sleep... this is keeping me up!)

mate, i've spent the last week making a custom loom to fit an L cdi on my H1 and lose all the road kit, i now know everything about the essential bits

its quite how big the pile of wire's i dont need is.

the black wire doubles back on itself and has a number of splices, off to the coil/relay/tacho etc .. so is asking for trouble really ..

then again .. maybe its your cdi after all ? was it the pin the black wire connects to that gave the duff reading ?

just gone back to the beginning of this thread and read it again ..

is it still stalling when you switch on main beam ?

if so, i'd guess at a short somewhere in the front section of the loom, something that's "grounding" the current in the broken black wire which is killing the coil signal.. the broken black wire being the cause for the lack of tacho, and sickly fuel pump ..

lighting wiring is all blue/red red/yellow IIRC.. and there's tons of it.

try unplugging the left hand switch gear (bypass the clutch lever switch) and see if its still playing up

I could only get one reading off the CDI in total, connection B to D but I can't remember the colour.

Looking at that diagram again and given that the coils are working (the rev counter has blown for sure) I'm now suspicious of the fuel pump relay even though it's been changed.

I don't envy you making a custom loom but I'll know may way round the standard one by the time mine is fixed!!

Edit; the stalling from headlights seems to have stopped since fixing the ignition switch and charging system. I think the difficulties I've had were caused by 2 different problems (the fuel pump and charging system) occurring at the same time with similar symptoms.

just read this thread as my zxr has been having similar problems which were sorted for a while by my mate splicing in some new wire into the loom but in general the loom is dead full of green dust instead of copper wire so i am biting the bullet i think and getting a new loom. £168.83 from DK motorcycles hopefully this will sort my problems not sure if its any good for you. im not to suprised my loom is knackered though as it is about 16years old and had a good bit of abuse over the years lol

Problem solved. Second new fuel relay sorted it.
I'm tempted to get a battery voltage display for the dash area to avoid similar problems in future.
Thanks for all the help!

sorted !