Newly purchased 86 zl600, off and on issues starting and running.

[flarider]

Hi,

I purchased a 1986 zl600, first bike I'm working on. The bike ran when I purchased it, but not well. I thought it would be solely carb issues since it started no problem. The issue was originally that the bike would suddenly rev high. The guy said he got larger jets, and that it just needed some tuning. I ended up putting everything back to stock since this is the first time working on a bike.

The carbs are cleaned and bench synced, and the spark plugs are brand new. The bike started and idled great, but would not rev past 5-6k rpm when the throttle was opened (however it would when the choke was opened up at first). However, the bike does not start anymore. I ordered new coils since I couldn't get a reading from these (which are the original coils). I couldn't find any specs on the cdi to test if that is bad, but I suspect the cdi is bad since it could have been running with increasingly bad coils, and it has been jumped a bunch with a dead battery. Haven't looked too much into the wiring yet. I'm looking to get a replacement cdi along with the coils, but I'm not sure the best avenue to go when purchasing a cdi. I tried searching the forums and the classifieds, but couldn't find anything. Should I just go on ebay? Any other troubleshooting recommendations?

Thanks

 

[R. J.]

You can down load the manuals in the technical section of our Forum. Was the bike jumped with a bootser jump box if so that can fry the CDI/ECU. It happened to our sport quad when my youngest son used my 200 AMP jump boost.

 

[Jarney]

Yeah, get the manuals from this site. And you can put an ad in the wanted section of this site, otherwise watch ebay and craigslist. Also check on the part numbers - sometimes they were used in other bikes and can be found that way. Give us some more info also -what is the bike currently doing - got spark, does it turn over, if not, does it make any noise - do you hear any clicking - things like that? Also check all your vacuum lines, but you may be on the right track - I think the 600's have cdi problems sometimes. Later.

 

[flarider]

I did get the service manuals. The first time it had an issue starting I went through the troubleshooting algorithm laid out in the guide, but it turned out that I had reconnected the plug wires wires wrong.

It turned over and idled fine, but when opening the throttle the bike would reach 5k or 6k rpm and cut out, then drop back down and climb back up and repeat if I held the throttle open. I tried running it on Friday and it started but then died out even though it was getting gas. Then it ceased to start. It did click though when I would try to start it. My multimeter wasn't reading any resistance when I tested the coils, so I purchased some new aftermarket coils, however, I did not restart the troubleshooting process again.

I know it was jumped from a car and another bike, and it was started with a battery charger connected to it at some point. Not sure if the settings or what it was doing because I let my friend handle that.

I should definitely go through the troubleshooting steps again instead of being lazy and check vacuum lines. I should also check the plug wires as well. When I do that I'll report back with better, more detailed information.

 

[furchin]

First as Jarney said, the 600's did have cdi problems, so you may be on the right track. I would unplug the cdi , check the connections, wiggle the wires and plug it back in. See if the bike fires. If not go to the download section for the 600 manual, it has the test procedure for checking the cdi. If you determine that the cdi is bad you do have options, first is to find a direct replacement, second is to find one from a 900/1000 as they will connect up but may alter the red line limits and maybe a few other things. Another thing that will make the 600 hard to start is valves out of adjustment. As far as high reving with the choke on this is common and should just be adjusted down as the bike warms up. Keep us posted.

 

[furchin]

With regard to the bike dying out while under load I would open the gas cap and see if it runs this way. The 600's have a filter built into the cap for venting and will go bad. If it runs this way simply remove the filter, it's about 3/8 inches in diameter and very easy to do.

 

[flarider]

Thanks for all the help. I will be working on it this weekend, so I will start troubleshooting then. If I do end up needing a replacement CDI, since they are known for going bad, I should get a new one, correct? Out of all the ones I saw on ebay, only one said it was working, and I don't trust that completely. Besides, if they go bad frequently, it could have been towards the end of its life when it was last used in a running bike.

As far as coils, I purchased aftermarket ones. Since they are just windings, and the service manual does not have different specs for each one, they are all the same and the voltage/current source and timing is done by other parts, right? I just found an aftermarket distributor, added one to the cart, specified a quantity of two, then proceeded to checkout.

And again, I'll go through the service manual troubleshooting steps this weekend, then report back with detailed information.

 

[R. J.]

I think the OEM CDI is discontinued. If you buy a used CDI from a 900/1000 or the connie 1000 the rev limiter will be set 500 rpms lower than the 600.

 

[furchin]

"I think the OEM CDI is discontinued."

Yes R.J., you are correct.

 

[flarider]

So if I need a CDI, best bet is a new aftermarket one, correct? I would think that if they have notorious CDIs, buying a used one from a bike would be a risk. Unfortunately, I did not have access to a voltmeter this weekend. But once I work on the bike this week, I'll post info. Also, I bought two of these coils:

http://www.ebay.com/itm/272316783001?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT

Hope I made an ok decision. Again, I didn't want the risk of used ones.

Would this CDI be recommended?

http://www.ebay.com/itm/CDI-ECU-Kaw...ash=item35d0df9d5f:g:8JEAAOxycmBS168p&vxp=mtr

 

[furchin]

the coils appear to be correct.
As far as the cdi, I have seen this listing before but have no first hand knowledge with it and I don't know of any member who currently uses one. I suppose it's worth a try.

 

[flarider]

Are there any recommended aftermarket ignition boxes then? Or do people usually go with used ones?

Still waiting on the coils after two weeks. I have the funds for an igniter. Since its such a common issue, and work takes up a lot of my time to work on the bike, I figured I may as well purchase the CDI, so I have it handy when I go through all the troubleshooting algorithms to minimize the number of times I have to work on a specific issue. If I end up not needing the CDI, I'll sell it or return it, but the time is more valuable than the money due to the nature of my work.

 

[furchin]

From what I know people mainly go with used cdi boxes. As I said before you could use one from a 900/1000 if you are not comfortable with one from a 600 as they were a noted issue.

 

[R. J.]

As noted before the rev limiter will be set at about 500 RPM less. I think a CDI/ECU box from a 85 to an 88 GPZ 1000 is set at about the same or higher than the ZL 600 CDI. A 250 Eliminators rev limiter is set at 13,500 RMP. Now that's singing.