"The white wire is the main power wire, brown runs the accessories and ignition, Grey turns the CDI on, Blue and Red turn lights on. There is an internal circuit in the switch that runs thru a 100 ohm resistor. You could bypass all that by running the white wire to one leg of a toggle, then connecting the rest of the wires to the other leg with a 100 ohm resistor added before connecting the grey wire to get your 6 volts." Thanks for help !!!!!! this is very good, working again. thanks a lot !!!!!!
The white wire is the main power wire, brown runs the accessories and ignition, Grey turns the CDI on, Blue and Red turn lights on. There is an internal circuit in the switch that runs thru a 100 ohm resistor. You could bypass all that by running the white wire to one leg of a toggle, then connecting the rest of the wires to the other leg with a 100 ohm resistor added before connecting the grey wire to get your 6 volts.
Hey man I have a ninja 500 and I need to hotwire it. I lost the keys and they don't sell them anymore. Which wires do I put together or what to hotwire it??? Someone pls help me out. I just got a charged battery and put it in
So this video also helped me out with my 1998 ZX9R! Got a Chinese ignition switch that was showing battery voltage and bike wouldn’t start. Moment I put in a 100 ohm, resistor on the gray wire: BOOM! Fired right up!
@@ionutfilip437 anywhere on the gray wire between the connector and the actual ignition works. I cut that section out and replaced it with the resistor, shrunk wrapped it and voila
My prob. Is getting tje fuel pump to come on all on a toggle and has been for a year or so bought new restior and it wont run power thru testing it at batt. Got a hundred of the dam things have tried 6 or so test light only have power on side to poss. Wont power tru ?
White wire to one post, resistor on the other post and only the grey wire attached to the other end of the resistor. All other wires would be bundle together and attached to the same post as the resistor, but not attached to the resistor
My problem is that a guy tried to hotwire my volcano classic.he cut the wires after the connector, couldn't get it to start and threw the connectors and ignition switch
ahhhhhh! i have been trying to figure out why my bike wont start for weeks. there is not spark in the spark plugs. i think this is why. cuz i sort of tried to hotwire the bike when i lost the keys. but i have keys now and still wont start. i am going to test the grey wire today or tomorrow and if it is wrong voltage what do i do? do i get new cdi?
so where does the neutral safety switch get its power from? Is it junction box or cdi box that said neutral safety switch receives its power from...thanks...
I've got this same bike. Ever since I got it it's given me problems. It'll run great for about 10 minutes and then it's like it cuts down to one cylinder and eventually just dies out completely. When this happens the cdi box is literally so hot I can hardly touch it. Replaced the cdi and had the same problem. Not sure exactly what's causing the issue. I have a theory but would like some feedback as to whether I'm on the right track or not. The guy who had the bike before me put a pair of those accel coils on it. There not specific to the bike though, they're more of a universal part. I have a set of stock coils (but without the wires) and I compared the 2. The stock coils test out at 3.5 ohms whereas the accels that are currently on it test at 1 ohm. I know when I did a lot of car audio work that hooking up an amp to run at 1 ohm vs 4 ohm, it would take much more power to run it and often the amps, if pushed too hard, would go into protection mode by shutting itself down. Do you think I'm having a similar issue with my bike for that reason? My theory is that the aftermarket coils are robbing electrical power that would otherwise be sent to the cdi box and as a result it overheats due to a lack of power. What are your thoughts? Am I way off with my theory or does it make sense that that could be my issue. Also, my cdi box, although will get hot and cut out, still works fine when the bike is first started for upwards of ten minutes. Does this indicate that the cdi is just fine and it's something else causing the problem, or will a bad cdi still work great until it's warmed up. Any advice would be very much appreciated.
Scott Stalmack Do you have the Float Bowl Mod? What are your idle screws turned out to and the float heights? I would start with the fuel side and work towards electrical. How long do you have to wait until it will restart?
I honestly don't know if it's got the float bowl mod. I'll take a look into that. Idle screws and float heights I'm not sure either. Haven't even really considered the thought of going through them cause when it runs, it runs great and doesn't seem to have a fuel delivery problem. The bike will usually fire back up after about an hour of cooling down. I'll def check the info you asked for about the carbs and I'll look into all the fuel system components to see if there's a problem there but I'll be honest it just doesn't seem like a fuel issue. If it is I guess I'm confused as to how the fuel system would cause the cdi to overheat and cut out. Not disagreeing with you by any means, just curious what would cause that to happen. Also, what's this float bowl mod you speak of? And lastly, thanks for the response.
Scott Stalmack The float bowl mod is removing the air valves and having the float bowls vented directly into the air box. If the carbs are not jetted and set-up correctly the bike can end up running too rich. It seems to me your engine is flooding out causing the stalling and no hot restarts. It all depends if the FBM has been done, the needles are stock/Dynojet or Factory Pro needles etc. Basically you'll have to pull the tank and the carb rack and see what has been done. Is this bike fairly new to you or has the issue just recently popped up?
It can be, but a lot of it has to do with the float bowls venting too much into the airbox creating an over-rich condition on a hot restart, especially if you have done the float bowl mod.
so I ran the white wire on one side of toggle and the rest on the other side with the resistor in between the grey wire if somebody have a video or a pic so I can make sure I'm doing it right I would appreciate it
Should be a Grey wire at the CDI. Back probe the connector with the Key-On and make sure the voltage is 5-6 volts. Anything over 6 volts the engine won’t start and obviously if a wire and/or connector is broken and the CDI sees 0 volts the engine also won’t start.
What does it mean if the voltage of the gray cable of a 1994 Kawasaki ZX 750 is above 9 volts. I have a problem with this motorcycle that doesnt spark, i would appreciate it if you could help me
Hi does this apply to a 95 Kawasaki zx7 too? Mines only starts if pull in clutch and release pull in release until it starts..also if go o long ride i get off eat or something..i go to start it wont start.
@@BullittOutdoors thank u. Like just now i went start it and had to pull clutch in and release probably 6 times or more until it starts. But wont start unless i do that even though its in neutral.
Does the ECU need to be plugged in when I’m probing the connector? I assumed without the ECU plugged in, as long as the ignition is hooked up to a battery source and I turn the ignition to On it’ll give me the bolts
going through all this trying to sort my no spark on my 03 636. you need the connectors for the ecu plugged in and you have to backprobe. Theres one 100ohm resistor in the bottom of the igntion barrel and the other is in the cdi/ecu. To halve voltage you need two resistors of the same values in series. By checking with connectors unplugged you will get battery voltage because youve disconnected the 100ohm resistor in the ecu from the circuit@@simonnguyen3202
Would you know if the EX500r Ninja ign switch has that same resistor in the switch? My bike had an attempted theft and they cut all the ign wires and twisted them all together trying to start it. It hasn't started since.
Hate to keep bothering you with this but I have a new switch I bought for it that is for the 87 to 93 ex500r. Knowing nothing about the resistor, I bought it new for 1/3 the price of the right one because the wire colors and configuration was exactly like the one I "should" have bought. Apparently, the CDI would have been toasted when they hotwired it anyway but had it not, I had already plugged in this switch and tried it to no avail. I later found your video and said "OH CRAP"! lol Following your directions on how to test the switch, I discovered it sends a full 12v to the CDI. If I purchased a 100 ohm resistor and enclosed it into one of the old school inline glass fuse housings would that work as well as the correct switch? I can't really afford a $150 switch on top of a new CDI if I could possibly avoid it. And thank you so much for replying to my queries, having combed the internet your the only one who seems to know anything about this and the standard dealer reply is always, "bring the bike in and we'll test it". Jon
How did you go john? Ive been looking into by passing my ignition on a ex500 & it has the grey wire with the resistor but i cant figure out if i just need to put a resistor on the grey wire & then put the other end onto the 12v ignition wire because to reduce the voltage from 12v to 6v you need to use 2 resistors in line with a positive & negative on either end & then you end up with 6v between the two resistors. But everything i see on the internet is only showing & telling me to use only 1 resistor inline on the grey wire at one end of the resistor & 12v ignition source on the other side of the resistor. It would be good to know if you got your bike running again using 1 resistor (100ohm 0.25w) or was it your igniter (cdi box) fried when it was hot wired.
I installed an new ignition switch, now my bike cranks but wont start. Will cutting the gray wire and putting a 100 ohm resistor in this wire solve it??
Bullitt406 Aww you got many words now. Well great news chump, I JUST came home from work this morning, sorry I am NOT unemployed. You and little cheap OLD Ninja. I had a 2004 Ninja ZX900 back in 2006 when I sold it! Chump. You are the one stalking my videos talking shit. Now you do not like it. Awwww. D.A.W < figure out what it stands for, hint, Dirty
