ZZR-250 Ignition Problems

Nigel Allen wrote:
> Fitted the new ignition switch to the ZZR and got headlights, instrument
> lights etc. but no spark.
>
> Side stand was up, clutch was pulled in. Starter spins but no spark at
> either plug.
>
> Apart from "swap bits around from another bike", any ideas where to
> start testing?

I *think* it should crank over in neutral even with the sidestand down
and clutch out. If it cranks it should be sparking, unlike many older
Hondas the starter won't crank over a Kwak of that vintage while the
kill switch is off.

> Only thing I can think of is that when these little arseholes tried to
> steal it, jamming the screwdriver so far into the ignition switch
> screwed up the electrics and cause some sort of short into the coils or
> ignitor. However I can't see (from the wiring diagrams) how this could
> have happened.

That's pretty unlikely. Since both coils are non-functional I'd be
suspicious that the CDI is unplugged, or some vital wire to it has
been broken or disconnected elsewhere. If they failed on the
screwdriver-in-lock they might have though that they could hotwire it
- was there any damage to the wiring harness?

Also, is the new lock from a ZZR250 or "something similar"?


BTH
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Boxer is of the opinion:
> "Nigel Allen" <"dna at edrs dot remove this com dot au"> wrote in message
>
>> Fitted the new ignition switch to the ZZR and got headlights, instrument
>> lights etc. but no spark.
>>
>> Side stand was up, clutch was pulled in. Starter spins but no spark at
>> either plug.
>>
>> Apart from "swap bits around from another bike", any ideas where to start
>> testing?
>
> Kill switch?

From memory, it doesn't turn over unless the kill switch is set
appropriately. The 600 certainly doesn't (just went out to the shed to test
it). It's worth bearing in mind though, Nigel, since it only takes a
half-second to check, and can save much swearing. <grin>

- Matt
 >> Stay informed about: ZZR-250 Ignition Problems 

On 10/02/2008 9:05 PM, BT Humble wrote:
> Nigel Allen wrote:
>> Fitted the new ignition switch to the ZZR and got headlights, instrument
>> lights etc. but no spark.
>>
>> Side stand was up, clutch was pulled in. Starter spins but no spark at
>> either plug.
>>
>> Apart from "swap bits around from another bike", any ideas where to
>> start testing?
>
> I *think* it should crank over in neutral even with the sidestand down
> and clutch out. If it cranks it should be sparking, unlike many older
> Hondas the starter won't crank over a Kwak of that vintage while the
> kill switch is off.
>
>> Only thing I can think of is that when these little arseholes tried to
>> steal it, jamming the screwdriver so far into the ignition switch
>> screwed up the electrics and cause some sort of short into the coils or
>> ignitor. However I can't see (from the wiring diagrams) how this could
>> have happened.
>
> That's pretty unlikely. Since both coils are non-functional I'd be
> suspicious that the CDI is unplugged, or some vital wire to it has
> been broken or disconnected elsewhere. If they failed on the
> screwdriver-in-lock they might have though that they could hotwire it
> - was there any damage to the wiring harness?

Not that we could see - the main damage was to the ignition lock and
wiring to the same. I'll take another look but all the plastic was still
in place so it's unlikely.

I also read in an article that you have to be very careful testing IC
(as opposed to CDI) ignition - putting power on the coils for too long
can cook them. Given that the ignition fuse was blown I'm starting to
smell a new IC Ignitor on the horizon.

> Also, is the new lock from a ZZR250 or "something similar"?

Nah - thought of that - it was from a "real" ZZR.

I've got a friend looking at it at the moment - he's a sparky by trade -
albeit a domestic type sparky - but has a long bike history and used to
do his own spanners when he competed.

I've also got an ER-5 sitting here so we're contemplating swapping a few
bits around to see if we can get anywhere before we throw it in a van
and take it to Motorcycle Weaponry in Mona Vale.

Really starting to sh*t me.

N/
 >> Stay informed about: ZZR-250 Ignition Problems