Project Stoopid!

[Master Hack]

Back at this pile o parts, where it looks like the ignition control box has gone bad. It takes some special secret gizmo to test it. The dealer has this gizno, the box is $500+, so its a sure thing that the box no good.
Now l'm searching for a cheap hack. There is a pair of pickups sensing the trigger points on a disc driven off the cam. I quessing the pickups are "hall effect sensors", but l wouldn't know a hall effect sensor from bathroom effect sensor.
anyone got some tips or tricks for testing and identifing HES's. If they are in fact HES, it shouldn't be that difficult to hach another ignition on this thing? Right?
Surely someone here in this vast supository of knowledge has encountered a similar problem, and the easy, cheap solution?

 

[Edwin Spangler]

I only play with hall sensors, dont know how to test them BUT... Maybe if you search around racedepartment (overtake.gg), someone has spoken about it. LOTS of DIYers there and LOTS of things we use, use hall sensors.

Its just a small square that passes by (or near) a magnet and determines the distance between the two. You can use those distances to call certain commands depending on their translated numeric value.

Basically a contactless potentiometer thats also MUCH more accurate.

 

[Master Hack]

only play with hall sensors

l got questions fer ya. This is day 1 of this (ignition) venture, so l probably will be askn, real basic stuff. Be patient....
Here's what l'm dealing with. It looks as you described.

the spinna plate indicated by green has one square notch. 10 oclock position.
the 2 pickups (9 & 3 position)
there are 2 double coils one fires #1 & 3 the other fires #2 & 4.
the problem is the box that goes between the "hall sensors" and the coil is bad.
There needs to be some knd of circuit between the sensors and coil.
Got any ideas on that?

 

[Denny]

MSD 6AL?

 

[Master Hack]

That might work. I was considering trying some kinda mopar hackjob, but got hung up on the lack of a distributer. I'll look in to that.

 

[Master Hack]

being a distributerless application complicater things. The distributerless setups cost as much as the Kawasaki ignition box. My inner cheapskate is having "feelings". Anexiety, fear, and uncertany. I think l should retreat to my safe place, in my piggy bank.

 

[Denny]

Can you open up the black box and look for burned areas or broken solder?

 

[Functional Artist]

Hey T,

1.) Are you sure the part is "bad"?
IIRC that bike was wrecked
...& most wrecked bikes (& cars too) usually ran/drove fine, until they got into the accident

2.) Are there any used motorcycle shops in your area?
...as they may have something like that, just sitting on a shelf (or on a wrecked bike) in the back

 

[Master Hack]

Are you sure the part is "bad"?

No. But it has been screwed with by a clown without a clue, and the guy l got from.
History has proven it’s my luck…
l have a connection with the dealer and have left it with him for testing.
All the safety switches and things are wired through the ignition box. I don’t need that junk, and it complicates the wiring.
l have seen used ones on ebay, for a hunnerd bux or so. But then l still have the issue with the un needed stuff and buying another bad box.
It can't be that complicated/expensive hack sometings to make sparks....

 

[ezcome-ezgo]

Go get some Chinese food, open the fortune cookie, do what it says to do. Problem solved.

 

[Master Hack]

Things have slowed down here at the Mt. Top Lab, with zero progress i the last few weeks. I'm getting ready restart the wheels of progress. Exciting things are gonna happen, and l'm going to work on this pile o scrap also.
So, l've encountered a minor dilemma that l'm sure one of our knowledgable consultants will have an answer to.
The sparkplugs are down in a hole in the valve/cam cover. It requires a really thin wall deep socket of the usual 13/16 size. Being the creative genius l am, looked at the socket then the lathe, no problem. By the time l turned it down enough to fitin the recess, it cracked. The socket in question was old and could have cracked eons ago, and just made an appearance, who knows ?
Who sells a good really thin wall socket? Sure, Kawasaki, but they are purdy proud of it, and they can order it.

 

[panchothedog]

Just a thought or suggestion. Most sockets in the typical mechanic set ( the chrome looking ones we all use ) seem to be made out of a very hard metal. While it is strong, it looks like it gets very brittle when machined too thin. The sockets that are made for impact guns seem like they are made of a much softer metal. You might try turning one of these down to the diameter that you need. You already know who sells the " good really thin wall socket ". The proud boys down at the local Kawasaki shop.

 

[Denny]

I would just weld up the crack and remachine it. What have you got to loose?

 

[Master Hack]

would just weld up the crack and remachine it. What have you got to loose

That an idea!
I threw that one away
Still not thinkin clearly. I have a few more, l'll turn another.
Pancho had a good idea, but l only have one impact socket. I hate to f... it up also.

 

[ezcome-ezgo]

Amazon.com: SUNEX TOOLS 2626 1/2-Inch Drive 13/16-Inch Extra Thin Wall Deep Impact Socket : Tools & Home Improvement

Amazon.com: SUNEX TOOLS 2626 1/2-Inch Drive 13/16-Inch Extra Thin Wall Deep Impact Socket : Tools & Home Improvement

www.amazon.com

Not a big fan of the jungle store as it were, but sometimes in a pinch it can solve a problem.

 

[Master Hack]

So, spark plugs are 13/16 since time began, then they came up with dem little things, 5/8 or sumpthin like that. Sometime after the smoke cleared over there in Japan they came up with 18mm spark plags. A quick trip to the tool box l pulled out a 18mm deep socket fresh from Horrible Fright. End of dilemma!
the plug is about half size. Pic to follow.
A special thanks to son in law #2 for sayin"ya know those are 18mm, right"
Obviously l told him, "yeah!". " seriously?"

 

[Master Hack]

Got busy today and made some serious progtess ! Just a quick recap:
l took this pic:
then l put the plug back in the head.


that little plug is so deep in a hole it might be easier to get at from the bottom.

 

[panchothedog]

Looks like it's been quite a while since it was installed. Are they all that fresh?

 

[Denny]

What was the verdict on the black box? Did you get it to crank yet? Does it have spark? Does it run? Is it soup yet?

 

[Master Hack]

no, no ,and no!