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Project Second time lucky.

Discussion in 'Your 250cc Projects' started by Wade Wilson, Oct 17, 2017.

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  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    That is electrical, its the speed restriction circuit in the speedo/ignition unit. When the needle on the speedo hits 180 it changes the signal on the circuit and the TCI starts cutting the revs.

    Whats happening is the bike thinks your doing 180km/h and is limiting the revs before redline, circuit is most likely open ie someone cut the wire. Wiring a resistor in will kill the limiter, but unsure on the value needed.

    It can also be caused by having mismatched A/C model engine/electrics. Whatever model the engine is, ZX250A or ZX250C, you need complete matching electrics (harness, tci, junction box, switchblocks, gauges) for the corresponding model
     
    • Informative Informative x 1
    Linkin, Dec 12, 2017
    #21
  2. ShaneP

    ShaneP Well-Known Member

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    The zr250 balius uses the same motor but restricted revs, right? Could it be a balius ECU? But like Chris and Andy are saying, check you have right engine-electronics combination.
     
    ShaneP, Dec 13, 2017
    #22
  3. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    It is hitting a "limiter". The 16,000rpm limiter is only meant to work in top gear only, but can come on in all gears if the speedo isn't working properly or the wiring is not right. If you search this forum you will find some information about this issue. @kiffsta pulled a ZXR speedo apart to find the little sensor that controls the limiter...find that thread as it has all the info you need.
     
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    Frankster, Dec 19, 2017
    #23
  4. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    Well, I took my speedo off to discover that there are only 2 sets of wired going to it, each set turns ont he tiny globe to illuminate the speedo, there are no other connectors to the speedo at all.

    -EDIT- Could this be because I have a 240km/h speedo?

    -EDIT 2- Just found the post that @kiffsta made, my speedo doesn't have that pug coming out of it, and my loom doesn't have the plug for the speedo either.

    -EDIT 3-
    Engine Number: zx250ceo48437
    Frame Number: 6u900zx250cc11979

    My engine and frame are both C model, and from what I can see that speedo plug is only from an A model.

    -EDIT 4- I found the pink wire on the CDI, followed it back and found the pink wire on the loom, it feeds into a 9 pin connector that plugs into the gauge loom, but it isn't actually connected anywhere.
    0b6a8e2ffc.jpg
    f4135397b7.jpg 8980cf3b92.jpg
    Since it goes no where, can I still put a 10ohm resistor on it and earth it, or splice it into one of the black/yellow wires?
     
    Last edited: Jan 2, 2018
    Wade Wilson, Jan 2, 2018
    #24
  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Check the connections on the igniton box under the left hand tail fairing. Is there a pink wire... if so, run a bodge wire from the pink wire on the speedo to the ignition unit and see how it goes.

    EDIT: Or is there not one coming from the speedo/tacho? If so, then your idea of a resistor and earthing it sounds good.
     
    Last edited: Jan 2, 2018
    Linkin, Jan 2, 2018
    #25
  6. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    no speedo wire, looks like a resistor and an earth is my only option.

    -EDIT- Wired in the resistor into the pink wire, then spliced that into a Black and Yellow wire (pretty sure those are earths) managed to get the bike to 19,000 in neutral in the drive way.

    Going to take it for a ride tomorrow and see if it works properly.
     
    • Winner Winner x 1
    Last edited: Jan 2, 2018
    Wade Wilson, Jan 2, 2018
    #26
  7. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    Well, turns out under load that I'm still stuck at the 16000 limit. I'll check the wiring again when I get home and see if it's wired up properly

    -EDIT- Just had a quick look, my wiring job seems to be OK, i'm going to see if I can splice it closer to the CDI and earth it somewhere else.
     
    Last edited: Jan 3, 2018
    Wade Wilson, Jan 3, 2018
    #27
  8. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    So far this is what I've done.

    Wired a 10 ohm resistor into the plug end and spliced it into an earth (black and yellow): 16000rpm limit
    Wired a 10 ohm resistor into the CDI end and earthed it to the frame: 16000 limit
    Wired a 10 ohm resistor into the CDI end and earthed it to the battery: 16000 limit
    ran a wire with no resistor to the negative on the battery: 16000 limit.

    -EDIT- I am actually retarded... I thought it was supposed to be a 10 ohm resistor, its actually supposed to be a 10,000 ohm resistor.
     
    • Bummer Bummer x 1
    Wade Wilson, Jan 3, 2018
    #28
  9. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    So just an update.

    I was riding in the rain, and the bike started to stutter really really badly, ended up dying on the side of the road. I thought it was water in the fuel, and sometimes the bike would start.

    found out that there was no spark, so i replaced everything from the coils down.

    Turns out my CDI was flooded with water and has now rusted away all the internal components. So I need a new CDI.

    buuuuuuuuut

    I cannot find a replacement CDI, I know my bike is a C model, but the CDI it had was a 21119-1316, blue label with a big K. and all the CDI's I can find for a C model are all 21119-1322 (Blue J) or 21119-1263 (Red B)

    Anyone know the differences between them?
     
    Wade Wilson, Feb 19, 2018
    #29
  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    I might have one, I replaced my TCI with a Lixianda unit from aliexpress.

    I'll have to dig it out of storage.
     
    Linkin, Feb 19, 2018
    #30
  11. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    Just found out the CDI that was on my bike was a ZR250 Balius CDI :confused:
     
    Wade Wilson, Feb 19, 2018
    #31
  12. ShaneP

    ShaneP Well-Known Member

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    So you would have had a 16k redline from that?
     
    ShaneP, Feb 20, 2018
    #32
  13. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Can you post the CDI number please. It will help others who may encounter the same issue. Also, did you sell off your Tyga kit?
     
    Frankster, Feb 21, 2018
    #33
  14. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    21119-1316 (i believe) was the CDI number, and No, I didnt sell the tyga kit.
     
    Wade Wilson, Feb 22, 2018
    #34
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