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engine swap 650 USA motor to 650 4k0 motor no spark

Discussion in 'XJ Technical Chat' started by matthew fitzpatrick, Jan 10, 2015.

  1. matthew fitzpatrick

    matthew fitzpatrick Member

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    As the title said swapped motors and now no spark changed the pick ups but still nothing does the 4k0 and USA motor have different wiring into the block connector to the igniter tcu box or. Would be something else like kill switch problem etc as it cranks fine but just won't spark getting really stuck as it's a bobber project and so close to being back on the road just need to get it running cheers in advanced everyone
     
  2. Rooster53

    Rooster53 Well-Known Member Premium Member

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    How are you checking for spark? You should check one plug at a time while all the others are connected and installed to complete the series current path of the wasted spark system. 1 and 4 form one series circuit with the secondary of the ignition coil. 2 and 3 form another series circuit with the other ignition coil secondary.

    Do you have a DMM to check out the secondary resistance of the coils and the caps?

    Also, if you have a DMM it would be a good idea to ohm from the TCI connector to verify the pick-up coils and wiring have the correct resistance. Some models use 4 wires for the pickups, some use 3 with a common depending on the year.

    If the wiring is stock, the kill switch will not only remove power from the TCI and ignition coils (no spark), but will also remove power to the starter cutoff relay and the bike would not crank. If the harness or safety circuit was modified, then yes the kill switch could be an issue. It is a simple test to verify that the 12v ignition routed through the kill switch is present at the TCI R/W (Red/White) wire. Place DMM negative on ground, DMM positive to the R/W wire on the TCI mating plug, should have 12V present when the ignition switch is turned to on.
     
  3. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Check your fuses
     
  4. matthew fitzpatrick

    matthew fitzpatrick Member

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    Checked fuses didnt check each plug and thats the problem one engine has a 3 wire pick up the other one is 4 wire
     

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