Hi, new to this forum.
Ive just finnished building a Mini Buggy that is powerd by a ZRX1200 04 engine.
The motor will start but icant get it to Rev past 5-6k and if you open the throttle fully it beaks up.
I suspect the IC igniter to be faulty or the ignition switch.
I have checked the following areas by the book!
-Pick up coil
-Ignition Coil
-Carbys clean and set-up
-New aprk plugs
-Correct fuel pressure to carbs and no blockages/fresh fuel
-Air box and filter

During the build the ignition switch was replaced by toggle switches and i noticed there was a resistor between the grey wire and the Brown wire on the ignition barrel, there is no info on this in the shop manual and ive searched the web also.
Dose anyone have any idea about this Resister?
NEED help, been doing my head in for days
thanks

 

I recall mention of the mysterious grey wire from a previous post, I beleive the concensus is that its a part of the anti-theft system, which is why it doesnt show up on the wiring diagrams. If you are getting it to start at all then the grey wire should not be an issue.
I have had similar problems in the past, usually a problem with the fuel supply. Carb check, good gas, and fuel filter solved mine, but since you have done all that already, I cant think of anything else. Sorry I cant help.

Welcome to KF!

 

Yes the mysterious grey wire, i dont think its part of the anti theft.
If i run a 100ohm resister between the grey and the brown wire(ignition key switch)
i get a weak spark, remove the resistor and short to brown i get no spark.
Tried different value resistors but no spark.
I need more info as to what this grey wire does

 

Im also new here. I tihnk were having the same problem. I jsut posted a thread (03 zx12 spitting and sputtering) HELPPPPPPPP

 

OK....Ive sorted the grey wire issue(resister and side stand wiring)
But now have a new problem,Motor kicks and splutters at 5000-5500 rpm if you go more than 1/2 throttle
Im guessing that its a jetting issue.
Anyone got info or link on carb tunning for the ZRX?......PLEASE!

 

Sounds like a bad mix to me, dont have a link to help you out, was the motor running before you put it in?

 

Motor was bench tested but not under load ofcorse, it ran fine.
I have noticed some plumbing around the carbs that dont look right and there is no info in the Kawi book on it ,
maybe u can identify it and tell me where they go or what they do.....Im refering to the tube between the carbs in the picture (block offs have been fitted)


[ATTA[ATTACH]3252

 

what did your kawi book tell you about the coil spring in that pic? Are you sure that the carbs are of a standard state(factory)?

 

My carbs have T-fittings between them that go nowhere, looks like yours are the same.

 

coil spring?? Im talking about the hose fitting.
the carbs are Factory spec Keihin CVK36.

Prom:Can you block off the fitting? whats it do?