Zr 600 Efi "no Spark"

[moondrifter]

I have a 1998 ZR 600 with the batteryless EFI. This past winter i burnt a piston and the oil seal. So i rebuilt the whole thing pistons, whole crank rebuild bearings and everything, honed out ect. Earlyer I had problems with it not running so great on both cylinders up untill about 4000 rpms. After i rebuilt it I took it out and it run like crap. It was only on one cylinder. After about five miles it just bogged right down to the point where it wouldnt go above idle. So i shut it off thinking it was the plugs and i never got it started again. The sled now has no spark and i just replaced the coil. Everything internal is just fine. I am thinking that it is a kill switch or the stator but i am not sure. It has no spark at all and once in a while it will get a waek spark just to fire it but it will never start. Does anybody know what this could be. Any help would be great!
Thanks! Nate

[Spaceman]

I vote for stator.

[moondrifter]

How would i go about checking the kill switch or stator to see if they are bad? I really need o get this thing fixed

[Erik B]

Since you rebuilt it I'm guessing you pulled the engine and after my own recent experience with dropping cylinders and weak spark I'd recomend starting with the cheap easy stuff and make absolutely sure that your ground wires are tight... Ask me how I know.
HTH
Erik

[moondrifter]

well erik I have been trying to get this sled to run right for quite a while. And i think I finally got it narrowed down to the stator or the kill switch(something in that area.) But I just need input on what people think is going on here. I will ask you though ,how do you know?
Thanks!

[puree]

if you have any spark at all,,, even weak,,, then your cdi is good,,, I would also assume that your coil is good since it is brand new,,,,
you can use a multi meter and check the resistance of your stator without having to pull it out,,,, you can also bypass all your switches with the 4 prong connector. if you bypass your keyswitch, killswitch, throttle switches, then you are down to your stator,,,, unplug your 4 way connector that is down near your stator,,,, try to turn it over,,, do you get any spark at all??? do you get weak spark??? if you get good spark, then you have a bad switch somewhere,,, if there is no difference, then you may have stator problems and its time to use a meter and test it,,, I started a topic in here about 3 weeks ago called zrt testing help,,, take a look at that post, it tells you what wires I had to test to see that my stator was good,,,, I cant tell you if yours would be the same measurements that I had or not, but I doubt it,,,, maybe someone in here has the specs that you need to test yours out,,,,

good luck
Brian

[tunedbyear]

if you don't have a service manual. i'd get one before you go any further. money well spent.

[Spaceman]

The kill switch can be unplugged at the base of the handlebars thus eliminating it from the system.

[puree]

here is a pic of the 4 way plug that will bypass all your kill switches,,, give it a try and see if you have any spark,,,,

the service manual idea is also a good one,,,, they arent too expensive at all and can be a life saver at times

[moondrifter]

Yeah, that was the first thing I did, was buy a manual. But the manuals dont give you too much information about testing things like this. but thanks for the picture and the kill switch advice I will try that stuff tonite and let you guys know if I have spark
Thanks! Nate