I have an 1987 Suzuki lt500, the wires are butchered,
I was trying to clean up and fix the wiring harness because
the lights were not working and somehow I lost spark!! I probably
didnt plug something in right or forgot to ground something...
I dont have a manual and was hopeing someone could help me with a
schematic or wireing diagram...

If you can help please email me:
lasthotrod@aol.com

Thanks...

 

I might be able to help. I'll have to look to see if I have a diagram, but I do have a brand new, in the package harness for a Zilla if your interested.

Denny

 

Whats you price on the harness??? Have any other electrical parts??
I tried all weekend to get spark, maybe something else is wrong,
I ran the wires directly bypassing the on and off switch and lighting,
The lighting wire (yellow and red) shows power, I have no idea how to check the rest...
the slator is a new junkyard piece but was very clean, maybe the harness or the coil?? The CDI Box?
I rode the quad then shut it off and cleaned it, then i was cleaning up the wireing harness (was extreamely butchered) and since then NO SPARK....!!!!!
Unreal....


Email me...

 

Same prob I had. Started with no spark. Course I found the bike buried in a field. I had a butchered harness as well. This is what I found. The previous owner had no spark so he started in on the magneto.He pulled the magnet off and damaged the excitor coil(small strands were broken) He cut off the key switch and wrapped the two switch wires together.
First thing I did was re wrapped the excitor coil (crap shoot but I got spark once I disconnected the two wires that were wrapped together at the ignition switch) The coil burned out so I replaced the excitor coil for 40 bucks from the dealer(you can buy the excitor coil only and solder it back in the stator plate. Check the junkyard one with a tester or battery and low amp light bulb if you don't have one.
If you see know spark take an old spark plug and smash the trode down to leave min gap. This will tell you if you are getting any at all. Or hold the wire while you kick-Not recomended though

The excitor coil is the small coil with the fine wires-It runs to the "trigger" small 1x1 box inside the stator plate.
My ignition wires were cut when I got the bike,they were then wrapped together. My bike runs with them apart.

 

I'm just wondering about you finding this bike buried in a field, what was it in mud or something? Sounds like a gold mine to me. Tell us some more info on this--hey give us the whole story for all I care, sounds like an awesome one!!!

 

OK... Here I go...The father an law has about 20 acres where we go ride. My son has an LEM 50 and I usually ride his polaris(wimpy)He is a serious junk collector that has everything you can imagine in a pen way in the back.(trucks engines tractors sleds and really anything he can buy for next to nothing)
I knew it was out there for a couple years now but never got to it.A coupekweeks ago I went out there and gathered all the plastic up box of parts etc... All the pieces were there but the screws.Apparently years ago it got passed around to a bunch of people because it didn't run. So every (I will call them folks from the hills) body that worked on it screwed it up a little more.After scraping all the bird dung off it I started to look at wiring coil etc...Whoever worked on it prior to me cut the ignition switch off coil wires etc... What a mess !!!!So far I blasted painted,replaced wiring clips,new screws(many of these),excitor coil, "firing trigger" I think its called. The excitor coil wasn't the prob originally it was the trigger. That small module just to the lower right of the stator plate however the people that worked on it prior damaged the excitor coil.Got the spark I neede so I put the bike back together.Ran about 6 laps across the 20 acres which by the way takes about 3 seconds on this bike before I had to brake in a panic !!!!!.....The bike stalled so I looked at the plug. It was smashed with small alum pellets You know what that means. Took the jug off last night and found a smoked piston. Best I can think is that either my timing is advanced or the 32.1 oil gas mix I used was to lean. I did line up the statr line to the case line. After I get a new iston ect,,, I will decrease the timing a little unless someone gives me some better advice.The bikes in good shape though.The aftermarket fenders etc... will need to be adjusted to fit better around the seat and stuff, but I was anxious to see what it would do.The brother in law has a built banshee so once I get this one running right(by the way the quadzilla is .80 over. I think all I will need to beat the banshee will be a pipe and jetting unless I am underestimating it.
Oh and more open space than the 20 acres. I appreciate any advice because I know nothing about this bike. Any specs, requirments,maintanance etc...(manual would help)

I'll get a little fun on it this summer and then begin to trick it out around winter. I'm gonna mill about .40 off the head once I start putting the paiston and rings back in. Will I need diff jetting?
I 'll try to post some photos....Any info on riding places near Mich is a plus....

 

To all,
By the way.... Sorry for the lengthy. I am just fired up about this machine.Fastest 4 wheeler I have ever ridden....

 

HEY GOOD LUCK WITH THE ZILLA!!! LETS US KNOW HOW IT TURNS OUT.

 

I re-wired my zilla about a year ago, I just pulled everything out and started from scratch, I took the on/off switch/lights completely out of the loop and wired the ignition to a kill switch. If you pull your tank and look at the connectors, the zilla's wiring is pretty straight forward. You can actually buy connectors and wiring and redo line for line, as long as the stator end is good. The only thing that ever went bad on my wiring is the coil. I would suggest if that if you have to start replacing parts, make the CDI the last, because they are not cheap, unless you can find a good used one.

 

id like to remove the key ignition and make the headliht to wear i can put it on when i need it.. how would i go about removing the both of these form it and what wires do i cut... i have some quick disconnect wire clamps to use for the headlight what wires should i cut ... and would a pair of aftermarket halogen headlights be to much for the stock stator.......
thanks