I believe you've got the ignition coils wired the wrong way, as normally the LEFT ignition coil fires #1 and #4, with the RIGHT inition coil fires #2 and #3.
Ignition Coil Primary And Secondary Wiring
Ignition coils on the 80’s Kz1000,Kz1100’s and Gpz1100’s are wired the same, that is as you sit on the bike, the LEFT ignition coil primary(small wires) are two wires, RED and BLACK. The secondary (or sparkplug wires) go to #1 and #4 sparkplugs(your primary wiring may be different).
The 550’s, 650’s, 700’s & 750’s are backwards to what is listed for the bigger 4’s.
The cylinders are numbered left to right as you sit on the seat; #1,#2,#3, and #4.
For the RIGHT ignition coil, the primary wires, again are two wires, RED and GREEN, with the secondary going to #2 and #3.
The RED wire gets it’s voltage from the run/stop switch on the right handlebar switch pod. Your primary wiring may have a different color.
The BLACK and GREEN wires connect to the IC Igniter(if the bike has the Kawasaki supplied electronic ignition) it actually gives the coils their grounds to fire the sparkplugs.
Primary(small wires) side of the coils will read between 1.8 to 3.0 ohms.
Secondary(sparkplug wire ports)side of the coil will read between 10.4K to 15.6K ohms. These ports are wired together, so it makes no difference which is used, as long as the correct coil to sparkplug configuration is followed.
The sparkplug caps should read 5K OHMS(5000), any higher, or a reading of infinity means new caps should be ordered. When re-installing the old or new sparkplug caps, cut about ¼” off the sparkplug wires for a new un-corroded connection.
To stress the ignition coils, take a hair dryer, heat the coils and see if the ohm readings change from cold to hot . If they do, it’s time to buy new coils.
Keep in mind, the wiring is reversed for the 550’s, 650‘s,700’s, and 750‘s, that is the RIGHT coil primary will be two wires, RED and BLACK with the secondary(sparkplugs) going to #1 and #4.
The LEFT coils primary wiring would be again two wires, RED and GREEN, with the secondary(sparkplugs) going to #2 and #3.
An indication of black and sooty sparkplugs may not mean a carb or carbs are in need of cleaning, but may mean the input voltage is low.
When checking the input voltage to the ignition coils, first have a fully charged battery, and the using a multimeter, set it up to measure VDC(Volts, Direct Current), range of 20.
Put the RED probe from the multimeter on the same terminal that either a RED wire or ones that’s RED with YELLOW stripe, and the BLACK probe on either a good frame/Earth ground or the battery Negative(-) terminal/post.
Depending on the motorcycles current draw( lighting, and other high amp needs) the reading might be 10 volts or more, but if the reading is down around 8 volts or less, this indicates a corrosion or wiring problem needs correcting to improve input voltage to the coils.
These engines have what is known as a “Wasted Spark” that is, a sparkplug will fire during an exhaust stroke. It does no damage and many other motorcycle engines have this design.
And here's how to ohm test the pick up or Pulsing coils, the ones inside the CD sized right engine cover:
Ohm Checking Pickup(Pulsing) Coils
The pickup(Pulsing) coils on the Kawasaki’s with the factory supplied electronic ignition can sometimes fail or become intermittent due to heat and vibration.
1.Trace back from where the pick up coils are mounted,(BEHIND A RIGHT SIDE, CD SIZED COVER) locate and disconnect a small 4 pin connector. Using a multi-meter set on OHMS and range of 2K, check between the BLUE and BLACK wires(#1 and #4 sparkplug wires) for between 360- 540 OHMS.
2.For #2 and #3 sparkplugs the wire colors will be YELLOW and RED, again 360-540 OHMS. The 550’s,650’s & 750’s may be backwards to the Z1’s,Kz900’s,Kz1000’s & Kz1100’s.
3.If the pickup coils are suspect of failing due to heat, they can be stressed using a hair dryer without the need of the engine running.
4.A replacement set of pickup coils might be obtained from a dealer who serviced the police Kawasaki’s.
5. If replacement pickup coils are not available, your next choice would be to order a Dyna “S” electronic ignition system from
www.z1enterprises.com It replaces the IC igniter with a smaller module located where the mechanical ignition advancer was mounted.
6. Checking with Kawasaki.com website has determined that the Pick up(pulsing) coils are available . The pulsing coil # is 59026-1133 and replaces the older # 1002, 1012 which were used from the MKII motors until the 2005 P24.
7.Check the small 4 pin connector that the pickup coils connect to for corrosion/loose pins too.
