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Help More starting issues - ZXR250

Discussion in 'Kawasaki 250cc In-line 4's' started by Wade Wilson, Jan 22, 2016.

  1. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    This is beginning to drive me insane. My bike is having serious problems starting. It will start if it's been push started or jump started.

    It generally starts with a bit of hesitation for the first start of the day, and as the day progresses it slowly gets harder and harder to start.

    I retested the coils and found out they were good, I didn't take the plug ends off last time I tested them. I have new plugs in as well.

    I had the battery tested at Battery World and its got 151 CCA (battery is rated for 140). When the bike is running, i've seen the stator charging the battery at about 13.5.

    Even with a full battery or a jump start, the spark is extremely weak, I also noticed that the voltage into the coils was only about 9-10 volts, is that normal? or should it be 12 volts? I also got some strange reading from the plug that goes into my Reg/Rec (some wires had no voltage, some had anywhere between 5 and 9 some had 12.) but I don't really know if thats normal or not I can't find anything in the manual about it. My reg/rec plug also has some pretty burned wires.

    I've looked for as many places that I could have a leak, I've disconnected everything electrical from the bike that isn't needed for it to start, and I still haven't found any leaks or shorts.

    TL;DR: Coils only seem to be getting 9-10 volts. will start only once with a full battery. Battery was tested and it's fine. will start with a jump start but kind of hesitant, does push start and start after about the 3rd try. Can't find any leaks or shorts, I don't have enough beer to deal with this bike anymore and I suck at electrical problems.

    There's probably more things I've prodded with the multimeter but I can't remember at this point.
     
    Wade Wilson, Jan 22, 2016
    #1
  2. kiffsta

    kiffsta Senior Member

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    test your voltage reg, this video will show you how



    Here is STu's write-up for the stator

    http://2fiftycc.com/index.php?threads/howto-testing-a-motorcycle-stator.2052/#post-18075

    Your burnt wires could well be the cause of your issues, can I suggest you swing by Jaycar as they sell replacement plugs with , you will need to cut and solder new tails on and then use some heat shrink to make sure the joints don't go to ground

    http://www.jaycar.com.au/Interconne...otive-6-Way-Plug-Socket---250-Series/p/PP2068

    The connector is known as a 250 Armlock connector
     
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    kiffsta, Jan 23, 2016
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  3. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    Just tested the Reg/Rec and it's reading one way but not the other way, so its working normally... I think.

    I did the Online battery recharge test earlier today and it was charging at about 13.5 volts.
     
    Wade Wilson, Jan 23, 2016
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  4. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    How many volts are you getting to the coils when you crank the starter motor?
    Sounds to me like it may be a bad earth through the coils or engine block to the frame. Try a jumper wire from battery negative to the bolt on the coils and see if it improves voltage. What about taking a wire from battery positive to the coil positive and see if it starts then.
    If giving 12 volts to the coils makes the engine burst into life at the touch of the button, then you must have a bad connection somewhere.
     
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    Murdo, Jan 23, 2016
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  5. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    I'm getting anywhere between 6 and 9 volts when I crank it. I'll try hooking the coils up to the battery to see if that does anything.
     
    Wade Wilson, Jan 23, 2016
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  6. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    I rewired the Reg/Rec, and I noticed the voltage to the coils jumped from 9 volts to about 10.5 volts. The bike started a few times with what fuel was left in the carbs as the tank is off getting welded.

    I tried pouring a little fuel down the fuel line and starting it a while later and it wouldn't go, i'll try again tomorrow once I get the tank back.
     
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    Wade Wilson, Jan 23, 2016
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  7. Mclaren

    Mclaren Well-Known Member Contributing Member

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    With reg ur right only work one way
     
    Mclaren, Jan 23, 2016
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  8. Peter079

    Peter079 Active Member

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    Try starting with the clutch pulled in. Just a thought.
     
    Peter079, Jan 23, 2016
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  9. Aaron81

    Aaron81 Active Member

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    All great answers and points to check listed above :) Another thing if I may would also be to have a look at the wires from the battery terminals and look for any green corrosion, if over looked the positive and earth can get really clogged with the stuff over an extended period of time.
    If you do find something of the sort remove said cable/wire and pour boiling hot water from kettle or something over the wire from down 1 end so hopefully it will flush all the crap out from the inside of the coating.
    Also dont rule your battery out just yet, yes it shows a higher read and yes it shows that there is 13.5 going to the battery when charging but it could be a case of the battery only holding a surface charge and after giving 1 or 2 good starts you could be back to dead battery again.
    Note- what I have done in the past as far as fuel supply without tank supply is to go to supercheap or one of those fine top of the line places :) and grab yourself an oil injector (This is a big syringe looking thing) Pull the plunger out of the center, hook your fuel line to the tip and fill her up. Just make sure you find a good stirdy spot to hold the container as you don't want to pour the stuff all over the bike when winding it over :)
     
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    Aaron81, Jan 23, 2016
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  10. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    There's no corrosion on any of the terminals on the battery.

    I did a resistance test from the positive on the battery to the coils and there was about 25-30 ohms of resistance, so I traced it back and found that the starter relay has about 25 ohms of resistance from the 2 connector bolts while the ignition was on, I couldn't find any info on it, but is that normal?
     
    Wade Wilson, Jan 24, 2016
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  11. Aaron81

    Aaron81 Active Member

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    Sorry mate, I mean the actual wire cables that run to the terminals, main +positive that connects to the starter motor and the battery and the main -neg that runs from the neg terminal to the engine as the main earth contact.
     
    Aaron81, Jan 24, 2016
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  12. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    I'm going to pull down the bike some more tomorrow and check those, I did some resistance test on my IC Igniter and I don't know if its broken or if I'm just doing it wrong but I was getting some seriously weird readings from it.
     
    Wade Wilson, Jan 25, 2016
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  13. Aaron81

    Aaron81 Active Member

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    Be sure to let us know how you go :)
    Main reason I kept on trying to explain the wires I was talking about is I had a situation with my old R1 and one of my old zzr250's where the one if not both of the leads had clogged up with a green chalky substance which was stopping the starter motor from getting the desired amps in order to wind over the motor, it would wind over very sluggish then all I would get would be a ticking noise from the starter solenoid.
    Electricals can be a P.I.T.A at times so best of luck in the hunt :)
     
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    Aaron81, Jan 27, 2016
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