600Z Tenere problems

[fireblade123]

Hi all, just new to the forum. Bit cheeky but I hope someone can help save me putting my head in the oven lol. I bought a 1990 600Z import a year ago as a project. Due to health problems I am just getting on with it. It ran when I bought it just needed some tlc, can't get it to run now, no spark. Have done all the usual tests and found the stator coil housing was full of engine oil, drained it and dried everyhing out but still no spark. Anyone any ideas please.

I have attached pic of the actual model.

[steveloomis]

The stator runs in oil, that is normal. Sounds like a problem I had, ran fine, then no spark after sitting for a few months. I tested my stator output that powers the cdi and the trigger coils. Both had ac power when kicked over so I figured correctly that the CDI had died. Very common with the age of these bikes.

I think I am correct in saying your bike still uses the CDI type of ignition. You will find it under the tank, above the engine between the frame gussets behind the steering head. If yours has wiring coming out of the module instead of built-in plugs you have the old style CDI.

Do you have access and know how to use an AC volt meter. Can be a digital type set for ac and 20 volts or so. Do you have a schematic? I can copy mine into a JPG and send it to you. Just PM me with your email address.

Happy to assist you in finding your problem.

Steve

[fireblade123]

Thanks for that Steve, I have a voltmeter but no schematic. The only info I can find does not relate to this model, wiring colour codes, resistance readings etc. So it should spark when using kick start?, how did you remedy this long term?,. There is a blue wire that comes out of the CDi unit, any idea what it's for?. I would like to restore the bike but need to get it running to assess the condition and viability.
Many thanks.
John H

[fireblade123]

Originally Posted by steveloomis

The stator runs in oil, that is normal. Sounds like a problem I had, ran fine, then no spark after sitting for a few months. I tested my stator output that powers the cdi and the trigger coils. Both had ac power when kicked over so I figured correctly that the CDI had died. Very common with the age of these bikes.

I think I am correct in saying your bike still uses the CDI type of ignition. You will find it under the tank, above the engine between the frame gussets behind the steering head. If yours has wiring coming out of the module instead of built-in plugs you have the old style CDI.

Do you have access and know how to use an AC volt meter. Can be a digital type set for ac and 20 volts or so. Do you have a schematic? I can copy mine into a JPG and send it to you. Just PM me with your email address.

Happy to assist you in finding your problem.

Steve

Can't PM as yet so my email addy is john@jhrhodes.freeserve.co.uk
Cheers

[bubbla]

...as the bike run until storage, I would start checking all wire connections, as well as kill-, side stand- and ignition switch. Might be just corrosion.
Good luck!

[fireblade123]

Originally Posted by bubbla

...as the bike run until storage, I would start checking all wire connections, as well as kill-, side stand- and ignition switch. Might be just corrosion.
Good luck!

Thanks for that, I have done all that over and over.
Cheers

[fireblade123]

Thanks for the replies, much appreciated. Nothing through yet MEZO. I will check out all the suggestions, thanks Steve,
ATVB John

[fireblade123]

Originally Posted by Mezo

Odd? that went hours ago? check your spam filter or spam inbox.

Mezo.

Hi, did that, nothing.
Cheers

[fireblade123]

Originally Posted by Mezo

Odd? that went hours ago? check your spam filter or spam inbox.

Mezo.

Found them, thankyou.

John

[fireblade123]

Hi guys, have tried all suggestions and a replacement CDI unit and coil, still nothing. very frustrating.
Cheers

[Walkabout]

Originally Posted by fireblade123

. very frustrating.

Maybe try the logic of a fault finding flow chart?
Diagnosis Center - Helping you Find the Problem - ElectroSport

Fault Finding Guide - Motorcycle Electrical Fault Finding Chart - ElectroSport

[bubbla]

Check your CDI for a black/white cable.
This cable delivers the shut off signal to the CDI (coming from ign. switch,
kill switch etc).

With ignition off there will be ground/minus.
With ignition on, kill switch on, neutral gear there should be no ground/minus.

If you find always ground/minus disconnect the cable and check for spark again.

Keep us updated

[fireblade123]

Originally Posted by bubbla

Check your CDI for a black/white cable.
This cable delivers the shut off signal to the CDI (coming from ign. switch,
kill switch etc).

With ignition off there will be ground/minus.
With ignition on, kill switch on, neutral gear there should be no ground/minus.

If you find always ground/minus disconnect the cable and check for spark again.

Keep us updated

Thanks for that but already tried it, no joy.
Cheers

[fireblade123]

There is an unconnected dark blue wire coming from the CDI unit, as far as I know it was like that when I bought it running??. Not shown on the diagrams I have.

[steveloomis]

I already replied via email but I just had a thought, try grounding that blue wire. This will signal the cdi that the bike is in neutral, won't hurt to try. Perhaps on your bike the neutral switch to CDI was bypassed and now goes directly to the neutral light from the switch.

For clarification for others reading this. The Side stand switch is an input to the CDI as well as the Neutral switch. Side stand wire is blue/yellow stripe. Neutral is dark blue (says sky blue on schematic) coming out of the CDI but is the SKY BLUE pigtail with bullet connector that goes on to the neutral light. Hooking the dark blue from the neutral switch to the sky blue directly will bypass the CDI. If you use the zeeltronic unit you will have to do this and ground the solid black wire. If your bike never had a side stand switch then the zeeltronic should plug directly in with no changes. With so many variations around the world and because the side stand switch is so temperamental and usually bypassed I suggested to Borut to just make the simple 8 wire CDI. Hyperpak make an 8 wire, 10 wire and 11 wire model. I think he builds the units as ordered and can make it any way you want. I ordered mine with the 8 wire and did the above bypass. Works great this way.

I hope this helps any who decide to go with the Zeeltronic or Hyperpak unit.

Steve