Race wiring loom!

[alimcgoo]

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

[noelb]

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.

[richie400ss]

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

[richie400ss]

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

[masterofinsanity]

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

[alimcgoo]

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

[masterofinsanity]

well done, glad you sorted it.

[Henchy]

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.

[Dolts]

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

[jake]

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

[alimcgoo]

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.

[jake]

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!

[Alan P]

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

[jake]

excellent.
Thanks Alan

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

[Alan P]

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