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ZR250 Balius non starter

Discussion in 'Kawasaki 250cc In-line 4's' started by adam.balius, Aug 5, 2014.

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  1. adam.balius

    adam.balius Member

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    Just finished stripping, cleaning and reassembling the carbs, i didn't find anything abnormal so i'll have to see how it goes tomorrow. Also going to buy a multimeter to test the coils.
     
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    adam.balius, Aug 7, 2014
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  2. adam.balius

    adam.balius Member

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    Just finished reinstalling the carbs, priming them and testing the coils as per the zxr 250C manual i download. the coils are within spec, float bowls full, carbs cleaned and it still wont start. Interesting thing though, when i took the vacuum hose off the petcock and blocked it with my thumb the bike nearly started then when i plugged one of the two pipes which go from the top of the carbs to the airbox it also nearly started. Could someone please explain to me what each one of these 3 hoses is supposed to do.
     
    adam.balius, Aug 8, 2014
    #22
  3. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    I'm fairly certain that the hose that goes son top of the airbox ends up being plugged into the vacuum valve. Another hose (I cannot remember if it's the larger or the smaller) goes from the Vacuum valve to the petcock and the last goes from the petcock to the carbs.

    [​IMG]
     
    Wade Wilson, Aug 8, 2014
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  4. adam.balius

    adam.balius Member

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    Thanks for the diagram. I cant seem to locate the vacuum valve anywhere on my bike. It's very odd plugging and unplugging the hose from the carbs to the petcock (hose off petcock, covering and uncovering it with my thumb) makes it splutter and occasionally backfire out the exhaust. the other 2 hoses that come off the top of the carbs dont seem to do anything whether they are plugged or not.
     
    adam.balius, Aug 8, 2014
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  5. Murdo

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

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    Are the plug wires on correctly? Haven't been mixed up?
     
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    Murdo, Aug 8, 2014
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  6. adam.balius

    adam.balius Member

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    yes plug wires are on correctly.
     
    adam.balius, Aug 8, 2014
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  7. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    Tomorrow I'll have a look at my bike and get some pictures/videos going for you.

    Sounds like you might have some hoses mixed up.
     
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    Wade Wilson, Aug 8, 2014
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  8. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    1 coil for cylinders 1 and 4 .... the other coil 2 and 3

    Heres the vacuum module on the C model

    Vacuum.jpg
     
    GreyImport, Aug 8, 2014
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  9. adam.balius

    adam.balius Member

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    Thanks Wade that would be great. Yeah 1 coil for 1&4 and another coil for 2&3. Just had a look at the bike again, cannot locate the vacuum valve anywhere.
     
    adam.balius, Aug 8, 2014
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  10. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    sounds like its missing then
     
    Th3_Huntsman, Aug 8, 2014
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  11. adam.balius

    adam.balius Member

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    Anyone care to explain what it does. Just been searching for an explanation of what it does but can't find anything.
     
    adam.balius, Aug 8, 2014
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  12. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    i beleive it creates extra vacuum so your bike sucks fuel and air in (possibly to actually start it....)
     
    Th3_Huntsman, Aug 8, 2014
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  13. adam.balius

    adam.balius Member

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    Hmmm sounds important!
     
    adam.balius, Aug 8, 2014
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  14. Wade Wilson

    Wade Wilson Beaяs Premium Member

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    All I know is my bike doesn't run properly without it.
     
    Wade Wilson, Aug 8, 2014
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  15. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    On the C model PRIME setting on the fuel tap allows fuel to run at any time ...including with bike off
    ON and RES operate via vacuum and no fuel flows with bike off

    On the Hyosung , theres no fuel tap at all ..... fuel auto flows via vacuum with ignition on.
     
    GreyImport, Aug 8, 2014
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  16. kiffsta

    kiffsta Senior Member

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    I have searched high and low for a ZR250 manual, but no luck so far, the best of my knowledge the Balius doesn't have a vacuum valve, there are 4 hoses off the Carbies, these being

    1. Fuel line from the petcock (line in)
    2. 2 breather hoses from the top of the carbies which go over the top of the air box
    3.
    4. The 4th is the return line from the carby boots which goes back to the petcock.

    The return line usually goes from the carby boots, I would assume 1 and 4 are linked by a T piece that has a single line to go back to the petcock, then 2 and 3 are looped together to form a seal. ( from memory that's how it is done an A model ZXR250)


    I would be making sure that the boots are done up nice and tight and that the 4 lines off the boots are free from leaks as you may be sucking in heaps of air which is causing your issues.

    Maybe @TwystedThrottle can help as I wanted his Youtube vid for inspiration , this Vid will at least show you where the top 2 breather hoses go on the airbox -



    See the pic below from a ZXR250, 1 and 4 join up at a T piece then it goes to the vacuum valve and 2 and 3 join at a T piece then go back to the petcock, as you don't have a vacuum valve, I would try a single between 2 and 3 with no T piece and then make sure that 1 and 4 come back to a T piece then go to the petcock.



    zxr250.PNG

    top2.PNG
     
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    Last edited: Aug 8, 2014
    kiffsta, Aug 8, 2014
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  17. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Same here .... no parts cat either
     
    GreyImport, Aug 8, 2014
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  18. adam.balius

    adam.balius Member

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    Okay. I had to take some time off from working on the bike to sort out my car problems (Aint life grand :D). Anyway last night I decided to test the CDI with a multimeter and after going through the (numerous) steps I discovered that the CDI output wires to the coils, both 1/4 and 2/3 have no resistance and test as an 'open circuit' on the multimeter.

    Upon closer inspection of the CDI box I discovered that it had been opened up at some time and 'resealed' with black RTV. I pulled the innards out of the CDI box and discovered what appears to be glue from a hot glue gun on the circuit board. Im no expert but this must mean something.

    So now im trying to track down a new CDI, the problem is that after much Googling of the numbers on the current CDI I have discovered that the numbers seem to be Balius specific. Im sure another ZXR250C CDI will work and have contacted someone who has 2. Both are 10 pin (6/4) but have different number and letter codes on them.

    The numbers on mine are;
    21119-1383
    131800-5950
    12V TNCF29 A

    And the two available are;
    21119-1322
    131800-5580
    12v TNCF18 J

    and

    21119-1842
    131800-5960
    12v TNCF30 B

    So basically I have these two to choose from but I don't know what (if anything) the difference between them is bearing in mind both are from ZXR250C.

    cdiglue.jpg zr250cdicode.jpg
     
    adam.balius, Aug 16, 2014
    #38
  19. kiffsta

    kiffsta Senior Member

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    I checked my spares bucket and all I have is a 21119-1415
     
    kiffsta, Aug 16, 2014
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  20. Murdo

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

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    Wasn't there a post some months back about a place that can repair cdi's?
     
    Murdo, Aug 16, 2014
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