Hi all, I've been having some intermittent issues with my zxr250a recently with the worst being an electrical gremlim. I turn the key, all lights and everything come on as normal. But when I press the start button, all I get is a click from the fuse box and no crank. ( just confirming it is the fuse box I can feel and hear clicking and not the starter relay ). I've checked the grounds, cleaned the ignition switch and charged/tested and battery but no luck. I decided to cut open the box and to my surprise it was clean. Upon checking the 30a main fuse, I noticed the starter relay was actually quite hot. Then when pressing the ignition, I could feel something moving in the starter relay but it was still clicking in the fuse box. Before rushing to buy a new starter relay, has anyone experienced something like this and would buying a new starter relay be the solution or would I need to consider replacing/fixing the fuse box? Thanks.
Looking at the wiring diagram for the ZXR250A the fuse box also contains a relay which in turn energises the main starter relay, it could be this that you are hearing. you should get a 12VDC signal on the yellow/red wire at the main starter relay when pressing the start button. If you don't and you hear that clicking sound the starter pilot relay (small one in the fuse box) contacts may be stuffed. At least thats the way I see it from the diagram.
1. measure battery voltage with everything OFF. volts = ??? 2. measure battery voltage when pushing START-button. volts = ??? If you suspect starter-relay, remove it, test and measure it and confirm it's bad before replacing.
I usually run a starter motor cable direct from the battery to the starter motor first. If starter motor is good then work backwards.
This ..... or even remove the starter and test it ... they are simple to remove and replace ... just be wary of the o ring The FZR400 had a buzzing starter relay ... changed it out and still buzzing and no start ... removed the starter motor and after a few slow revolutions it jumped to life .... reinstalled and away she went .... so the slightly "seized" starter motor was upsetting the electricals in the chain
