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Help zzr250 ignition switch swap

Discussion in 'Kawasaki 250cc Twins' started by Martin Green, May 30, 2022.

  1. Martin Green

    Martin Green Active Member

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    Hey all

    Im just trying to repair a 2002 zzr250. It has no key but I got hold of a complete lock set from an earlier model.

    Is it simply a security bolt head on these to get the ignition off? Like a Torx head with a small round knob in the middle? that's what it looks like.

    Also the ignition switch that I got hold of has 6 wires plus one just hanging free of the block and the old one has only 5 wires and no spare. Ive plugged in the replacement to try it and all lights up but it does not turn over. No click from the solenoid.
    Ive swapped the solenoid for a known good one so it's not that.

    Any ideas? Thanks
     
  2. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Either security torx bit or breakaway bolts that you have to drill the heads off and replace.

    Is the replacement genuine or aftermarket? If aftermarket, you might have to replace the electronics side of the switch (take the cover off and swap the guts) unless that was the problem to begin with.
     
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  3. Martin Green

    Martin Green Active Member

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    thanks Linkin

    it was just a missing key that made me loo to change it.
    I can pull the electrical sides out and swap them?

    that'll do it!
     
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  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    You may be able to do that. If it doesn't work, take the old electrics out of the switch and observe where each wire goes on the pad. You can then de-pin the new connector and match against the old one. If the old and new plugs are not a match, then take photos of the layout and swap the connector out. A pick or specialty electrical connector tool will allow you to re-use the connector. If the pin type isn't a match, you'll have to get some new pins and re-terminate. Crimping tool will be needed.
     
  5. Martin Green

    Martin Green Active Member

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    the replacement is from an older zzr250 but it has one too many wires and isn't getting power to the starter solenoid for some treason
    I will try to swap the lock barrel over to the original wiring.
     
  6. DannoXYZ

    DannoXYZ Well-Known Member

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    Security bolts may have smooth convex head. Just use spring-punch to make dimple in centre to drill off head with cobalt bit.

    Easier to just test contacts and re-pin connector as needed on new switch. Less chance of harming internal electrics.

    Post colour of wires you have on new switch along with photo of both old & new connectors showing wire locations. Then I'll post list of 8-10 test measurements to map out switch connections. Once that's done, it's simple matter to re-pin terminal positions.
     
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  7. Martin Green

    Martin Green Active Member

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    Sorted

    I removed the top yoke, drilled out the security bolts, swapped the electrics section over to the replacement lock barrel, new bolts, put it all back together and 'Bobs your uncle' it now does everything that it should.

    Thanks fop your help.
     
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  8. DannoXYZ

    DannoXYZ Well-Known Member

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    Good job!! :)
     

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