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Discussion Starter #1
Hey guys. I just added a new addition to my bike collection. A 1981 kz550 ltd c2. I believe it has electronic ignition like the vn750. So I bought it for $250, it needs work. I discovered no spark on all 4 plugs. I doubt the plug wires are bad cuz what are the chances of all 4 failing at once, right? I also doubt that both coil packs are bad at once. So i am thinking something else some where else is the system is bad. I noticed the IC ignitor was unbolted and just stuffed under the side cover, as if someone removed it for who knows why. It has two plugs to connect it to the wires in the harness. Could this be bad? what else would cause a total system failure assuming the fuses are good. I am leading toward one thing being bad to cause the whole system to not work. any help is very appreciated!

Chris
 

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The Reanimater
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Chris:

You can also try this place with your question.
http://forums.kz650.info/index.php


Hey guys. I just added a new addition to my bike collection. A 1981 kz550 ltd c2. I believe it has electronic ignition like the vn750. So I bought it for $250, it needs work. I discovered no spark on all 4 plugs. I doubt the plug wires are bad cuz what are the chances of all 4 failing at once, right? I also doubt that both coil packs are bad at once. So i am thinking something else some where else is the system is bad. I noticed the IC ignitor was unbolted and just stuffed under the side cover, as if someone removed it for who knows why. It has two plugs to connect it to the wires in the harness. Could this be bad? what else would cause a total system failure assuming the fuses are good. I am leading toward one thing being bad to cause the whole system to not work. any help is very appreciated!

Chris
 

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Discussion Starter #3
what is the purpose of the R/R
 

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Simple Solutions
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i dont know this bike u speak of but i have been workin on an 81 honda... having spark issues on this one myself.... the honda has a pick up coil in the motor opposite side the stator those signals run to whats called a spark unit then to the coils and plugs....

start with grounds , connections and wires.... and go through the circuit one at a time... check for voltage at the coils... look fo a service manual and googe the exact question u mayy get better more detailed answers ... id like to know what u find out .... sorry im not of more help but brainstorming helps me

.ive looked for other forums but none compare to this site ... .....


ive also heard that alot of the older japanese bikes have all these elec problems to always carry a spare j box...:pepper:
 

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Discussion Starter #5

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Discussion Starter #6
I will check the IC ignitor, which i think is the same as the "spark unit" you mentioned, and then move on. All 4 of my plug wires are completly stiff and brittle. Im hoping that it is a s simple as bad wires. Is there a way i can just buy the wires and attach them to the old coils? I know the wires can come off, but on www.kawasakipartsnation.com the exploded views show the wires being sold with the coil packs. So maybe i can find aftermarket plug wires?
 

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Simple Solutions
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Good an bad news. I decided to pull out the battery, b/c the numbskull brained idoit before me put the battery case in backwards, which jamed a bunch of wires. Also, he bought the wrong battery so it is too wide for the case so that is all smashed up. I am looking at a WHOLE new battery case. I went to www.kawasakipartsnation.com and parted it out. That whole setup including the battery is $150. Now the worst news. The rectifier has a 5 wire harness coming off it but a six prong plug. The second single wire is snapped at the end. I have no idea where this wire is suppossed to go. Also, the plug on the rectifier has 5 prongs, i think one is missing, b/c the female end on the bike has six slots. !!!!! i believe i can get a used rectifier from a wreck but i really need to buy the clymer shop manual for this bike to see the wiring diagrams.
 

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Discussion Starter #9
that single wire is seperate from the 5 wire harness. It is red and white. i have a huge feeling this is my problem, its just a tough time figuring out where everything goes.
 

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Discussion Starter #10
HOLD EVERYTHING! the hot line coming from the rectifier was not broken, but simply UNPLUGGED! so i poked around until i found where it is supposed to go. Pluggled it in, rewired the battery and got that whole mess fixed with the case. Tested for a spark, and I HAVE ONE! WOOT! So i think i can get out of this project for about $100 because i am missing some parts here and there. BUt i only payed $250 for the bike. Now that it has a spark, I KNOW i can get this thing running. It also has a crappy 4 into one exhaust that is all rusty black metal. I found a used $200 stock system online. All in all, i can have this bike running, polished up, waxed and working for about $600, and in the end have about $2,000 of power! haha
 

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Linkmeister Supreme
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HOLD EVERYTHING! the hot line coming from the rectifier was not broken, but simply UNPLUGGED! so i poked around until i found where it is supposed to go. Pluggled it in, rewired the battery and got that whole mess fixed with the case. Tested for a spark, and I HAVE ONE! WOOT! So i think i can get out of this project for about $100 because i am missing some parts here and there. BUt i only payed $250 for the bike. Now that it has a spark, I KNOW i can get this thing running. It also has a crappy 4 into one exhaust that is all rusty black metal. I found a used $200 stock system online. All in all, i can have this bike running, polished up, waxed and working for about $600, and in the end have about $2,000 of power! haha
Well, as the Aussies say, "Good on ya mate". I`m glad you got things worked out here. In less than a day too!!:wow:
 

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Discussion Starter #13
thanks guys. I got it running, not well but it runs. it sounds like it needs carb work if you open the choke the slightest bit it stalls, leading me to believe fuel delivery. I bet the jets and idle circuit are all clogged and gummed up. However, i discovered that, the head gasket is bad. I am getting a misty oily spray coming from there, and it is making a mess. it is leaking around cyl. #2, so it might have low compression but it is still fireing, hense the burn on my finger from feeling the header haha. I will just continue cleaning and polishing and fixing everything. Once i have it running well, then i will prolly pull the head and replace the gasket. Is it possible that the head nuts are just loose? It says they need to be torqued at 15 ft lbs, which is not a whole lot, could they have loosened up over 28 years?
 

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thanks guys. I got it running, not well but it runs. it sounds like it needs carb work if you open the choke the slightest bit it stalls, leading me to believe fuel delivery. I bet the jets and idle circuit are all clogged and gummed up. However, i discovered that, the head gasket is bad. I am getting a misty oily spray coming from there, and it is making a mess. it is leaking around cyl. #2, so it might have low compression but it is still fireing, hense the burn on my finger from feeling the header haha. I will just continue cleaning and polishing and fixing everything. Once i have it running well, then i will prolly pull the head and replace the gasket. Is it possible that the head nuts are just loose? It says they need to be torqued at 15 ft lbs, which is not a whole lot, could they have loosened up over 28 years?
never hurts to check... i have never experianced head bolts loosening and if they did i would assume it had a nasty vibration...
 

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Discussion Starter #15
yeah, same here
 
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