Ok so the sound check part, that's called a continuity test? Also for the starter test, when you say the small terminal you mean the non-copper colored one that bonzo labeled with the black arrow? And then leave the thick red wire on the copper colored one? Also, would it have been feasable that my donor had something like an imobilizer fitted which is causing problems now? It looks like there was something running off the yellow/black striped wire at the ignition as this wire was cut and has a terminal block connecting it now.

Yes keep the big wire on.

And yes your car did have an immobaliser, you should have a black box about 2.5" x 2" x 3/4" . which needs to be bypassed if not plugged in.

But we need to confirm a few things first before moving on.

TT

Right so I've done the tests again, please tell me I haven't fried my starter motor :o

First DC voltage test with the thin wire off the starter motor
Position 0
Red=12.71
Blue/Black=0
Yellow=0
Yellow/Black=12.65

Position 1
Red=12.71
Blue/Black=0
Yellow=12.71
Yellow/Black=12.65

Position 2
Red=12.71
Blue/Black=0
Yellow=12.71
Yellow/Black=12.71

Position 3
Red=12.71
Blue/Black=12.71
Yellow=0
Yellow/Black=12.71

So next I did the continuity(beep) test by putting the red probe to the red battery positive, then touched the black probe into the ignition plug.

Position 0
Red=beeped value 008
Blue/Black=no beep value 1
Yellow=no beep value 1
Yellow/Black=no beep value 1

Position 1
Red=beeped value 012
Blue/Black=no beep value 1
Yellow=no beep value 1
Yellow/Black=no beep value 1

Position 2
Red=beeped value 015
Blue/Black=no beep value 1
Yellow=no beep value 1
Yellow/Black=no beep value 1

Position 3
Red=beeped value 014
Blue/Black=no beep value 1
Yellow=no beep value 1
Yellow/Black=no beep value 1

Next I tried having the battery positive & negative connections on, the small red/black stripped wire off the starter leaving the thick red on the starter and the thick black earthed on the gearbox. I then took what looked like a thick black wire off the zx6r loom I have (an earth wire maybe?) and touched one side to the battery positive and then one to the bottom bolt (black arrow in bonzo's picture) and nothing happened...

the yellow black being live all the time is odd.

I think we also need a good picture of your starter and it's connections. I would pull it off the car and get it on the bench for testing.

TT

I think the power at the ignition switch should be as follows.

Position 0
Red 12v
Yellow 0v
Black/Yellow 0v
Black/Blue 0V

Position 1
Red 12v
Yellow 12v
Black/Yellow 0v
Black/Blue 0V

Position 2
Red 12v
Yellow 12v
Black/Yellow 12v
Black/Blue 0V

Position 3 (Engine cranking)
Red 12v
Yellow 0v (Disabled while cranking)
Black/Yellow 12v
Black/Blue 12V

Anything other than the above is not correct

looks about right Dave..

TT

So what's likely to be causing my black/yellow to be live all the time?

Pull fuses 20,21,22 and see if the Bl/Ye goes to 0V if it does then try removing each in sequence.

TT

Ignition switch could be knackered, wire shorting out inside the loom, something connected incorrectly.

Got to remember loom is nearly 20 years old, has been ripped out of a car, stuffed in a box, and then laid out on your new chassis. They do get brittle.

I am not using the sierra loom.


BBug, we can get it running without the main harness. But we need to make sure that starter is good .

TT