Discussion:
ER5 - hot wiring damage?
(too old to reply)
Kevin Stone
2012-11-12 10:43:14 UTC
Permalink
Hi,

Someone nicked my son's ER5 the other week, they wheeled it down the hill
and then tried to hot wire it (and failed), however, they did quite a bit of
damage trying to get it going.

We've rebuilt the top front (yolk, headlight, ignition barrel, clocks,
etc)...

Now there is no spark...

We've checked the obvious (plugs, leads, coils, battery, etc).

Could their failed attempt to hot wire the bike have damaged the IC igniter
/ CDI unit?

Other things we might have missed?
--
Kev
Mark Olson
2012-11-12 11:12:36 UTC
Permalink
Post by Kevin Stone
Hi,
Someone nicked my son's ER5 the other week, they wheeled it down the hill
and then tried to hot wire it (and failed), however, they did quite a bit of
damage trying to get it going.
We've rebuilt the top front (yolk, headlight, ignition barrel, clocks,
etc)...
Now there is no spark...
We've checked the obvious (plugs, leads, coils, battery, etc).
Could their failed attempt to hot wire the bike have damaged the IC igniter
/ CDI unit?
Other things we might have missed?
I would get out a test light consisting of a 12V bulb on a couple of
pieces of wire, and the electrical wiring schematic. Probe around to
verify that there is 12V where it should be.

It is possible they fried the IC Igniter but I'd be pretty surprised
if they did. You didn't mention the fuses, which would be the first
thing I would check.

Yoke, FFS.
Kevin Stone
2012-11-12 11:19:02 UTC
Permalink
Post by Mark Olson
Post by Kevin Stone
Someone nicked my son's ER5 the other week, they wheeled it down the hill
and then tried to hot wire it (and failed), however, they did quite a bit
You didn't mention the fuses, which would be the first
thing I would check.
Fuses appear OK, it turns over fine.
--
Kev
Ian Newham
2012-11-12 12:12:51 UTC
Permalink
Post by Kevin Stone
Fuses appear OK, it turns over fine.
A longshot but ISTR Kawasaki used to put a 100 Ohm resistor in the
ignition circuit and the CDI wouldn't fire if it wasn't present. This
was designed to stop people hot wiring and its not shown on the wiring
diagrams when its there.
I've only come across it on my ZX7R but it may have been done on other
Kawasakis. Like I said, a longshot but it would fit the symptoms
Kevin Stone
2012-11-12 12:16:47 UTC
Permalink
Post by Ian Newham
Post by Kevin Stone
Fuses appear OK, it turns over fine.
A longshot but ISTR Kawasaki used to put a 100 Ohm resistor in the
ignition circuit and the CDI wouldn't fire if it wasn't present.
If it was there originally where would this likely have been?

Somewhere we've replaced at the top end?
--
Kev
Kevin Stone
2012-11-12 12:18:52 UTC
Permalink
Post by Ian Newham
Post by Kevin Stone
Fuses appear OK, it turns over fine.
A longshot but ISTR Kawasaki used to put a 100 Ohm resistor in the
ignition circuit and the CDI wouldn't fire if it wasn't present.
If this was in the ignition barrel, shouldn't the new barrel include this?
--
Kev
Ian Newham
2012-11-12 12:23:50 UTC
Permalink
Post by Kevin Stone
If this was in the ignition barrel, shouldn't the new barrel include this?
I'll admit I've never *seen* it - just read stories of people mucking
about for ages trying to fix a 7R after someone has tried hotwiring it
or stripping them for the track. If you've replaced the entire ignition
switch with associated wiring I would have thought it would include it.
TOG@Toil
2012-11-12 14:18:00 UTC
Permalink
Post by Ian Newham
Post by Kevin Stone
If this was in the ignition barrel, shouldn't the new barrel include this?
I'll admit I've never *seen* it - just read stories of people mucking
about for ages trying to fix a 7R after someone has tried hotwiring it
or stripping them for the track. If you've replaced the entire ignition
switch with associated wiring I would have thought it would include it.
"I read it on the internet" ;-)
Ian Newham
2012-11-13 10:38:39 UTC
Permalink
Post by ***@Toil
"I read it on the internet" ;-)
<Blush> but in my defence I do own that bike and its bloody weird thing to
put in there.

I'll crawl back under my rock now :)
--
Ian Newham
JB
2012-11-12 20:40:53 UTC
Permalink
Post by Kevin Stone
Hi,
Someone nicked my son's ER5 the other week, they wheeled it down the hill
and then tried to hot wire it (and failed), however, they did quite a bit
of damage trying to get it going.
We've rebuilt the top front (yolk, headlight, ignition barrel, clocks,
etc)...
Now there is no spark...
We've checked the obvious (plugs, leads, coils, battery, etc).
Could their failed attempt to hot wire the bike have damaged the IC
igniter / CDI unit?
Other things we might have missed?
Neutral light or clutch switch or associated wiring? On most Kwaks, there is
a special 'safety' circuit which cuts the spark if the neutral light is
out/failed and the clutch switch isn't in.
Check the blue/red trace (clutch switch and pale green wire for neutral.
Does the neutral light work ok?
Just don't ask me how I found out this little gem.......
JB
Kevin Stone
2012-11-12 22:33:22 UTC
Permalink
Post by JB
Post by Kevin Stone
We've rebuilt the top front (yolk, headlight, ignition barrel, clocks,
etc)...
Now there is no spark...
Neutral light or clutch switch or associated wiring?
We didn't bother wiring the neutral light back in.

Will investigate that as well.
--
Kev
Pip
2012-11-12 23:27:33 UTC
Permalink
Post by Kevin Stone
Post by JB
Post by Kevin Stone
We've rebuilt the top front (yolk, headlight, ignition barrel, clocks,
etc)...
Now there is no spark...
Neutral light or clutch switch or associated wiring?
We didn't bother wiring the neutral light back in.
Ah.
Post by Kevin Stone
Will investigate that as well.
Might well be worth it ;-)
--
Pip: Keeper of the Cable Ties
JB
2012-11-13 07:34:17 UTC
Permalink
Post by Kevin Stone
Post by JB
Post by Kevin Stone
We've rebuilt the top front (yolk, headlight, ignition barrel, clocks,
etc)...
Now there is no spark...
Neutral light or clutch switch or associated wiring?
We didn't bother wiring the neutral light back in.
That will be it then.


JB
Loading...