3TJ/4JH Hybrid wiring nightmare

[Fitz]

An intermittent fault on my hybrid, whereby it would decide not to charge the battery and either cut out or leave me stranded with a flat battery, has developed into the bike now not running at all. I took out the wiring harness to strip the sheathing and found bare copper brushing against the bike frame, corroded crimps and wires just twisted together and skimpily wrapped in sellotape. Under the sheathing, it's been cut up, added to and spliced into so many places it's not recognizable as a 4JH loom. I'm in despair.

Whoever put this hybrid together was mechanically competent but electrically challenged. I'm surprised it hasn't burst into flames in the 3 years I've had it. 3 afternoons of tearing my hair out is enough! I think a fresh 4JH loom and start again from scratch seems best.

I've a couple of questions for the knowledgeable folks in the FZR Workshop...

1) Does anyone have a decent '94 4JH wiring diagram?

2) Does anyone by any chance have a 4JH loom?

3) On the outer extremities of the stator coils, the thin copper lines imprinted onto the flat plates closest to the magnets have worn away in places. Good continuity is still maintained through all three coil leads when resistance tested from the plug though. Would this mean a new stator is required?

4) When diode testing the reg/rec, the reading on one terminal is showing 10% more resistance than the other two although there is no reverse flow on any of them. Is the difference significant for normal functioning of a three phase alternator?

Hoping for some help.
Fitz

[barryfzr]

yep as per pm I have a workshop manual/diagram here.... pm us your address if you struggle to get one online

[fzrtim]

I think i have a 4jh loom some where in my garage as i bought one to remove the cdi plugs to adapt the 400 loom. It was off the FZR not the thundercat. It wouldnt be much of a job to transplant your plugs on to it. If you want you can have it for the postage (that is if i can find it!).
Also id be tempted to check the cables in the magneto. I had a problem when i first fitted my motor that 2 of the 3 cables had frayed where they had rubbed on the flywheel. Think it is a common problem if the cables are not routed properly.
Hope this helps

[cagiva996]

ill second that,my magneto wires had been cut by the flywheel too which caused endless headaches til i found the problem,worth a check!