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Help ZXR250 - No life in the starter motor (but where is it? )

Discussion in 'Kawasaki 250cc In-line 4's' started by Horst, May 30, 2015.

  1. Horst

    Horst Member

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    Had just got my ZXR 250 (1995) humming nicely and rego ready after being locked up for a couple of years when she karked on me. The starter motor won't respond to turning the key ..don't even get a click sound. So far I've checked the fuses and they look good.. so I have to look further. Ive found a great youtube vid (below) which gives instructions on how to locate and fix the problem (on some other sort of bike) but I cant find where the solenoid or the starter motor are located on my bike. I'm wondering if I can éasily access, pullout and test these components myself (as per the vid) or if its a tricky job which might best be handled by a specialist. Appreciate any help if you've handled this situation before.
     
    Horst, May 30, 2015
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    First thing to check is the condition of the battery with a multimeter ..... cold weather sorts out a less than perfect battery very quickly.

    http://2fiftycc.com/index.php?threads/how-do-i-test-my-12-volt-battery-and-charging-system.1794/

    Its more likely going to be a bad connection, damaged wire etc than total failure of a component

    Next step would be to check your connections to the battery then follow the negative lead to earth and make sure its grounding correctly

    then follow your positive lead that will head to the starter solenoid .... check theres no corrosion , loose fittings and damage
    keep following the wiring and it will lead u to the starter ..... same thing , check the connections and any problems there.

    Starter motor

    Starter.jpg

    As u can see everything is being ripped out and not in place but it shows wat the solenoid looks like

    solenoid.jpg
     
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    GreyImport, May 30, 2015
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  3. Horst

    Horst Member

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    Thanks heaps for those tips and pics .. Im pretty sure my battery is good (its new) so Ill check the wires and connections next.. and then access the pictured components. Your pics are especially helpful..much appreciated .. will let you know how I go. Cheers
     
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    Horst, May 30, 2015
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  4. Horst

    Horst Member

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    **** happens. My Kawasaki 250cc ZXR (1995) Grey Import is unusable just one day after passing the rego inspection test. What's up? I turn the ignition key and nothing happens. No signal lights on the front dashboard panels or anything, The whole electrical system is completely dead.

    It all started with the indicator lights going on me ..couldnt believe this happening just hours after the rego inspection test when they were all working perfectly. Anyhow after testing the fuses (all were OK) I figured it must be due to the flasher relay being faulty so I replaced it with an after market unit (model as advised by the bike shop) but without success .. the only result was to see the 10 amp fuse blow. Now for some o so dumb reason I saw a 30 amp spare fuse in the fuse box and put that in the 10 amp fuse slot for the indicator lights. The fuse didn't blow and the indicators (with the after market flasher unit) came on for a moment flashing at super high speed but then pop I fried some component elsewhere in the system so that now, as I said, the whole lot is completely dead. What to do now? Pleased to know if you have any idea as to which component or components I've damaged. I think the battery is still Ok and am thinking its the wiring in the ignition switch are or perhaps its the voltage regulator (if there is such a thing?).

    I like solving problems and despite having little experience with diagnosing electrical faults I reckon there's a chance that I could locate and fix the problem myself. I've seen some dyi you-tube vids that show how to locate electrical shorts etc and plan to get a multimeter and hopefully a wiring diagram that you guys have made available in the resources section to start the investigation. What do you reckon .. should I give it a go?

    Before going any further I have a question about the wiring diagrams which I see from a previous post from Huntsman to Brodie (copied below) I could access after joining up as a premium member. Is the manual and the section with the wiring diagrams all presented in English or is it in Japanese? and if it's not in English do you reckon ill be able to decipher it.?

    One final question.. Ive looked around the site on how to become a premium member but without any luck. can you please send me a link to the sign-up page.

    Thanks for your help
    Cheers
    Horst

    Hi Brodie,
    We have in the resources section a manual for the zxr250C
    Below are links to the electrical part which includes a wiring diagram.
    http://2fiftycc.com/index.php?resources/kawasaki-zxr250-service-manual-part-11.95/
    http://2fiftycc.com/index.php?resources/kawasaki-zxr250-service-manual-part-11.95/
    For access you need to become a premium member
    here is why
    http://2fiftycc.com/index.php?threa...premium-membership-workshop-manuals-etc.2123/

    Cheers
    Huntsman
     
    Horst, Nov 9, 2015
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  5. kiffsta

    kiffsta Senior Member

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    Have a look at your starter solenoid, there is a 30 Amp fuse in there which may have gone, I would be checking the leads to all your indicators and make sure nothing is going to earth
     
    kiffsta, Nov 9, 2015
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  6. Horst

    Horst Member

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    Hi Kiffsta.. You/re an absolute genious .. I have power back to the system after replacing the 30 amp fuse as you said.
    I'm over the moon with that. Now all I have to do is to find the problem with the indicators.

    BTW You''ll see Ive joined up as a premium member. It'll be great to have access to the manual..

    Thanks again ..just brilliant
     
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    Horst, Nov 9, 2015
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