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My 2003 zzr600 is only running on 2 cylinders, Ignition coil…

Customer Question
My 2003 zzr600 is...

My 2003 zzr600 is only running on 2 cylinders

Mechanic's Assistant: What's the make/model/year of your bike?

Ignition coil is good i tested it on the other side

Mechanic's Assistant: Have you checked the battery lately?

Put a brand new one in

Mechanic's Assistant: What is the model of your '03 motorcycle?

Kawasaki Zzr 600

Mechanic's Assistant: Are you fixing your bike yourself? What have you tried so far?

Yes i am, i jave checked for shorts in the wires for the coil that sparks cylinder 1 and 4 I tested to see if thr coil was bad, it works fine

Mechanic's Assistant: Anything else you want the mechanic to know before I connect you?

There are also no fuses blown

Submitted: 5 months ago.Category: Motorcycle
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Answered in 10 minutes by:
3/29/2018
Motorcycle Mechanic: Louie, Technician replied 5 months ago
Louie
Louie, Technician
Category: Motorcycle
Satisfied Customers: 13,585
Experience: 25+ yrs. experience
Verified

Hi and welcome to JustAnswer; an independent site with members providing product information, repair tips and technical assistance as a form of paid Q & A service.
My name is ***** ***** I'll be assisting you with your question regarding your "...2003 zzr600..."

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Customer reply replied 5 months ago
Hello, and thank you im hunter
Motorcycle Mechanic: Louie, Technician replied 5 months ago

Initially, which "...2 cylinders..." are running please?

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Customer reply replied 5 months ago
Cylinder 2 and 3 run
Motorcycle Mechanic: Louie, Technician replied 5 months ago

And do you have a multi-meter available?

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Customer reply replied 5 months ago
I do but i dont have betteries at the moment, the ignition coil for cylinder 1 and 4 does work thouhh i tested it by swapping it to the other side
Motorcycle Mechanic: Louie, Technician replied 5 months ago

I understand.

Still, I was hoping to test for:

  • IGN+12V on the red wires to these ignition coils;
  • pulsating voltage of the black and green wires from the I.C. ignitor to the ignition coils.

Incidentally, is the fuel pump working as expected? ...tachometer?

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Customer reply replied 5 months ago
Pulsating viltage is the reading while im rolling the bike over? Vould you let me know what my readings should be when i test for them? Im actually not sure if the tach works i jave seen the neetle move but i just bought this bike and when it was running no more than 500rpm which wouldnt read it
Motorcycle Mechanic: Louie, Technician replied 5 months ago

The expected voltages when attempting to startare:

  • 12V on both red wires to the ignition coils;
  • pulsating voltage from 12V to nearly 0.0V on the black and green wires.

The ignitor switches these 2 wires to ground thus the pulsing 12V...0.0V...12V...0.0V

Sorry, but "...dont have betteries at the moment..." for the multi-meter? ...or for the bike?

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Customer reply replied 5 months ago
For the multimeter i was thinking for future refrence. I just want know know all the tests i should do. Also could the cdi box be fowled even though on coil works
Motorcycle Mechanic: Louie, Technician replied 5 months ago

Yes, it is possible that the ignitor (CDI) to be (partially) faulty hence 2 & 3 coil's green wire gets driven but not (or weak) on the black wire for the 1 & 4.

It is also possible to check for spark with the spark plugs removed and left dangling/grounded to the engine. Please click HERE. Exercise due care and caution if would be attempted.

It must be posted that the black wire driving the ignition coil for 1 & 4 also drives the tachometer and fuel pump relay.

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Customer reply replied 5 months ago
I believe the fuel pump is working due to i had the bike running for about 5 min on the 2 cylinders
Motorcycle Mechanic: Louie, Technician replied 5 months ago

Try the spark test on all 4 spark plugs.

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Customer reply replied 5 months ago
I have they all have spark and i also cleaned the plugs with wire wheel
Motorcycle Mechanic: Louie, Technician replied 5 months ago

"...all have spark..." would indicate that it is not an ignition issue why 1 & 4 are not firing. The ignition coils are good as well as the ignitor.

It would then appear to be a fuel starvation concern.

Have you checked/cleaned the carbs?

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Customer reply replied 5 months ago
My apologies i thought you ment the spark plugs them self. There is no spark on cylinder 1 and 4. Only 2 and 3. But if the plug the ignition coil for 1 and 4 into the other side of the bike i get spark. Im not getting power or somthing to wires for the ignition coil for 1 and 4
Motorcycle Mechanic: Louie, Technician replied 5 months ago

I understand.

Could you try jumping the red wire for the 1 & 4 ignition coil to the red wire of the 2 & 3 ignition coil?

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Customer reply replied 5 months ago
Okay so i know its the black wire that goes to the fuel pump relay and tach.
Motorcycle Mechanic: Louie, Technician replied 5 months ago

Yes, the same black wire drives:

  • fuel pump relay;
  • tach;
  • ignition coil for 1 & 4.

And the same IGN+12 delivered to both ignition coils through their individual red wires.

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Customer reply replied 5 months ago
The red wires are delivering power but that black wire is causing the issue. What should be my next steps to determine why its failing
Motorcycle Mechanic: Louie, Technician replied 5 months ago

For test purposes / checking spark 1 & 4, (temporarily) disconnect the tach's and fuel pump relay's connections.

The idea is to let the IC ignitor drive only ignition coil 1 & 4:

  • see if either tach or fuel pump relay is robbing power;
  • or IC ignitor's output for the black wire is weak.
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Customer reply replied 5 months ago
I know where the fuel pump relay is located vut where is the tach relay
Motorcycle Mechanic: Louie, Technician replied 5 months ago

There is no tach relay. The black wire delivers pulses to the tach's electronics that interprets/converts the pulses to RPM.

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Customer reply replied 5 months ago
I bought new plugs and I got a circuit tester. The red wire lights up really bright bit the black wire is really weak even unplugged from the pump relay
Motorcycle Mechanic: Louie, Technician replied 5 months ago

"...black wire is really weak..."

Can you try do the same to the green wire? ...and compare with results of the black wire

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Customer reply replied 5 months ago
Green wire has strong current and pulsation also the ignition coil for 1 and 4 is pretty warm from me rolling it over
Customer reply replied 5 months ago
I also plugged the other coil to the 1 4 side and it got warm as Well but it doesn't warm up on th 1 3 side
Motorcycle Mechanic: Louie, Technician replied 5 months ago

Based on these results/observations, it would appear that the IC ignitor is (partially) faulty hence a replacement is warranted.

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Customer reply replied 5 months ago
What bikes would offer the same if igniter as this one? Just so I have a better much finding on that will work for this bike
Motorcycle Mechanic: Louie, Technician replied 5 months ago

2003 Kawasaki ZZR600 ZX600E IC Igniter P/N###-##-####br />Also used by 1995 to 2004 Ninja ZX-6 ZX600E;

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