OMR's New Girl.... 1997 Voyager XII (ZG1200-B11)

No not yet....

Here's where I'm at presently.

* Got the manual and familiarized myself with the components and locations.
* Have the fairing and plastic all off.
* Recharged the battery.
* Found a cobbled up mess of home mechanic wiring and some after market relays and switches...
:pinch: Hmmm, go figure. So corrected to OEM diagrams.
* I found the starter bypass switches (infamous clutch perch) dirty/oxidized, so I took them apart to clean.
* During starter button press, High pitch whine as if free running and clunk sound from the starter motor.
* Replaced starter motor with spare provided. No more whine.





She now turns over but I still get an occasional clunk, thoughts are starter clutch.... Damn, have to split the cases if that's the problem...

Same time, not going to do anything to that level quite yet.

Next step is completely go through the electrical troubleshooting and repair section first. Want to make sure all relays are working, that I have spark, the fuel pump is receiving it's control voltage and passing fuel, the CDI isn't blown etc....

Since she does turn over, if I can get her enough to start then go from there.

There you go, that's about it for now...

Here we go again!!!!!!!! :lol: :silly:

Update:

First thing first, Re-drew a wiring diagram that was easier to freaking read...


Well as expected due to shit home mechanic wiring and for the fact that PO had to replace the generator (internal rec/reg), starter, wiring harness.... the IC igniter was susceptible to damage.
I don't have spark to the coils->sparkies.

The manual provides a nice chart for OHM testing pin to pin... On several measurements I obtained, no doubt the IC Igniter is crap.... New OEM costs... $450... :pinch: :pinch: :pinch:





Ok, screw that.... Let's open up the IC igniter and see what we have shall we...
WTF do I have to lose...



Ahhhhhhhhhhhhhh based on the pin inputs that measured out of spec, follow them to these 2ea 2SD1071
High Voltage Amplifiers.... Ah soooooooooooooo....

Ok, hard to find onto e-bay....
I'll order 4 each and have some spares since these are so hard to find!


I'll keep you posted after the replacements. Hopefully a $450 costs will turn into a $10 repair!

Old Man Rock wrote: Update:

First thing first, Re-drew a wiring diagram that was easier to freaking read...

Well as expected due to shit home mechanic wiring and for the fact that PO had to replace the generator (internal rec/reg), starter, wiring harness.... the IC igniter was susceptible to damage.
I don't have spark to the coils->sparkies.

The manual provides a nice chart for OHM testing pin to pin... On several measurements I obtained, no doubt the IC Igniter is crap.... New OEM costs... $450... :pinch: :pinch: :pinch:

Ok, screw that.... Let's open up the IC igniter and see what we have shall we...
WTF do I have to lose...

Ahhhhhhhhhhhhhh based on the pin inputs that measured out of spec, follow them to these 2ea 2SD1071
High Voltage Amplifiers.... Ah soooooooooooooo....

Ok, hard to find onto e-bay....
I'll order 4 each and have some spares since these are so hard to find!

I'll keep you posted after the replacements. Hopefully a $450 costs will turn into a $10 repair!

So did you sneeze on that thing? :sick: :laugh:

No... Your GF's LUV Juice... :pinch: :whistle:

Need to get her to the clinic! :woohoo:

Hey OMR dont mean to jump in here other than to say she is a beauty and 1 mod I did to my goldwing that imp slims her down and doesnt effect its functionality is trimming the entirely too tall wndshield with a cutoff wheel looks like it was ordered that way

Old Man Rock wrote: Update:

First thing first, Re-drew a wiring diagram that was easier to freaking read...

Well as expected due to shit home mechanic wiring and for the fact that PO had to replace the generator (internal rec/reg), starter, wiring harness.... the IC igniter was susceptible to damage.
I don't have spark to the coils->sparkies.

The manual provides a nice chart for OHM testing pin to pin... On several measurements I obtained, no doubt the IC Igniter is crap.... New OEM costs... $450... :pinch: :pinch: :pinch:

Ok, screw that.... Let's open up the IC igniter and see what we have shall we...
WTF do I have to lose...

Ahhhhhhhhhhhhhh based on the pin inputs that measured out of spec, follow them to these 2ea 2SD1071
High Voltage Amplifiers.... Ah soooooooooooooo....

Ok, hard to find onto e-bay....
I'll order 4 each and have some spares since these are so hard to find!

I'll keep you posted after the replacements. Hopefully a $450 costs will turn into a $10 repair!

THAT is simply f'n awesome!

Haven't looked totally into it....just the schematic on bike bandit for parts....but the starter clutch might just be able to be had through the oil pan.. Maby...

I swear to God, my brain gets bigger every time I follow one of your threads, it's like realizing that not only am I not lost but I'm actually camping with Rambo and McGuyver.

Dave,

This just FYI....

Back in 86 we had a 600 Ninja come in with about 1000 miles on it...no spark.

Checked things over and swapped a brand new CDI box off a showroom bike....cured the problem. Gave the customer the new CDI and sent him on his way. Ordered a new CDI for the showroom bike [warranty].

New box arrives. Sat down with the service manual, the failed CDI and the brand new one. Tested them both per service manual using a Kawasaki Multi Tester.

NEITHER CDI passed according to the service manual resistance tests

It would be very, very rare to have both pickup coils fail on anything at the same time but check output on them and also the kill switch.

Resistance measurements versus powered on conditions can bite you, Most definitely!
I also considered the note on using "KAWI Measurement Tool" for accuracy of these measurements versus my fluke but other than a few of the measurements, all came within tolerance... Plus Fluke is a damn good DVM...

I found alternatives to the 2SD1071 that would most likely work but it would throw the resistance measurements off so chose to find the exact replacements. Not to mention might throw the ignition timing off a tad.

NOTE: I still have considerable electrical testing to perform yet.... Need the engine fully running to confirm charging system and such. all relays, inter lock out switches have been cleaned and tested. The CDI (Cruise control) well can't do that one yet.... Clarion stereo can wait as well.

The goal is just to get it to fire, then I can analyze other issues to see if it's worth the $$$ to complete the re-build. $500-%1000 total costs it'd be worth it. If a couple thousand, naw, sell it & get my my $1200 back for I can get a better build (running Voyager) for that costs.

I found used igniters on ebay for ~$200... Downfall they could have the same issues.... If it turns out this is all that's wrong with her, go for a new igniter then...

I'll keep you all posted, should be a week before getting the components from overseas.

Great work Dave. nice to see u going deep.
Keep at it, she doesnt stand a chance , you'll beet this thing, and she'll be running in no time.