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

SHE LIVES!!!!!!

OK, somewhat a long story so here we go and seriously, not making this shit up....

As mentioned, no ignition spark. So received the Darlington Pair Drivers from CHINA :blink: and installed, no spark but the igniter does have resistance measurements closer to specifications now.

All right, still have to verify fuel pump as well as NO ignition spark issues such as pickups (magnetic), coils and possibly still igniter.

To get to the fuel pump (Bitch) have to take off the rear frame to get the tank out... Are you fucking kidding me.... :laugh:

Check the fuel pump with starter, shot across the garage so that's all good...


Coils, spec is between 1K - 16K ohms cap to cap on the secondary, measured ~ 26K ohms... WTF, normally open, or partially shorted windings would read lower not 15K higher.... Hmmm, something wrong here....

Take some more fairing off to get to the coils, pull them out and the spark plug caps fell off... Holly shit, no wonder.... The voyager xii caps have the spear in them that thread into spark cable center conductor. So I remove the plug wires to measure just the coil secondaries, low and behold perfectly in spec....

Hmmm, these builds use resistive spark plugs and the PO asswipe mechanic he used added resistive wire... Possibly the reason it took out the Igniter drivers.... 15K additional load!!!!
Ok, off to Checkers for Mallory non resistive spark plug wires ~ $25 and install, still no Spark.




Time to check the ignition pick ups... NOTE: I had my O-scope with me for measuring pickup and ignition signals! With the sensors disconnected from the main harness to igniter, Ohm out the sensors themselves, within spec... Place the pick up near the crank rotor tab, fluctuates as expected...

Hmmm, Wait a minute... Ohm out (continuity) the harness plug to the igniter... INFINITE!!!! Now one conductor maybe but all 4 pickups are open, no freaking way!!!

Peel back the insulation and the pick up conductors as depicted in the schematic are Black/White, Blue, Black/Red, Yellow... The main harness was 3 Blues and a black... Again, WTF!!!!

Looked around and no other connector in the proximity.... BUT WAIT, the PO owner had a shop work on this for $1200 remember... Hmmmm, Snip off the tie wraps and BOING, a 3rd connector falls into view... Peel back the insulation and WHOLA!!!! Color match... Conitinuity check and sure enough, to the igniter....

Plug it up, pull the choke, press the starter and She purred to life w/in 3 seconds of starter button press!!!!

Total into the bike right now outside of $1200 purchase...
OEM Starter Relay Solenoid $25
2x 2SD1071 Drivers $10
Spark Plug wire Set $25
4 x New sparkies $10

Whopping Grand Total $70....
Classic moment, jipped him down from $2K to $1270....

Now comes the nasty part, clean and detailing this old girl, she deserves it....

Before:





After:





Still have considerable tune up, carb sync, engine and final drive oil changes, thermostat and water hoses, in-line fuel filter, fork & shock oils etc... but time is ok....

Seriously guys, exactly how it happened....

Dave

3 things strike me:

1) You know electronics
2) This bike wasn't loved previously
3) These bikes are not made to work on

Seems like it's found a good home eventually, the old girl

Just friken great. Now I have to look at that dam thing for a year. Glad you got the easy fix. gl nice bike

Looking very good. What was your secret recipe of detergents to get her looking so clean and bright?

Nice going OMR

Simple trick Larry turned me onto, crap is magic in a bottle....

Wow! :woohoo:

man OMR wish i had your electrical prowess.

Wifey Poos happy... Her Baby Lives !




Outside of the electrical repairs accomplished, still have some tune up's (carb sync, timing etc...) to accomplish... All rubber hoses, vacuum, gas lines replaced. New coil wires/sparkies, new Progressive shocks.

And a shit load of cleaning/degreasing w/Simple Green...

Pictures to come later on as I put her back together.

Congrat's, OMR! Love a happy ending. Looking forward to some beautiful vistas from your future Voyager trips. You're in the right part of the country for that type of bike. Enjoy!

Hey all,

First off, total PITA just for the damn starter clutch (excessive slippage)... Here in AZ, so hot these days don't feel like riding so no better time to get the starter clutch swapped out....

I have the engine out of the frame, all case bolts and associated components removed and can get the cases apart everywhere but one place.... :tho:

As can be reviewed in the image, catching/hanging up in the lower case under the flywheel and I can't see anything that would be catching nor any additional bolts (external or internal) that would not allow for the cases to split...

Everywhere along the cases no issues, only in this spot where it will only split apart ~ 3/8ths " and that's it....

Anyone have experienced this or have an idea...?

Thanks,

Dave