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Help 2KR Crate Motor - Wiring Help

Discussion in 'Yamaha 250cc In-Line 4's' started by Lynxdragon, Oct 19, 2016.

  1. Lynxdragon

    Lynxdragon Well-Known Member

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    Hey guys,

    Just recieved a motor I ordered for a 2KR, Its turned up in the frame minus its switch blocks.

    Already sorted out ign power by crossing the 4 wires where the keysw used to plug in. But needing wire colors on the loom for Clutch Safty switch, everything else I can think of is plugged in but no spark. :(

    Currently smashing a wire against the battery to crank the motor haha...
     
  2. Lynxdragon

    Lynxdragon Well-Known Member

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    Ps. Kill switch is already looped out too, so thats not an issue and has power there.
     
  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Clutch and side stand switch
    I have a 2KR loom here, but won't have a chance to look at it before about 10pm tonight
     
  4. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    This is the FZR400 wiring diagram(english), so it may help show you which wire's to look out for (as long as they're same colour's as your's ?)
    There is a colour coded diagram in the 2KR Service manual (must be a premium member to view it) but it's in Japanese

    [​IMG]


    From looking at my 2KR loom, and i'm only guessing here
    3/4 of the way back down the loom, just past the starter solenoid there is a Black, and a Blue wire in a black 2 terminal plug (fuel pump ?)
    Light blue wire for neutral switch
    Blue wire for low oil level from engine
    There is a Yellow there too (side stand?)

    At the back of the loom there's a black 5 terminal socket that plug's into a black plug with 5 wire's that go into a black square box (might be EXUP blanking/delete box?)
    There are also 2 red wire's that connect at a resettable 20A circuit breaker which has a clear removable cover on it
     
  5. Lynxdragon

    Lynxdragon Well-Known Member

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    Thanks for that, fuel pump isn't an issue because I'm just looking for a spark.

    I have a fzr250 3ln from my street fighter project, but the wire colours seem different and so are the plugs. I'm fearful that the coils or tci is f****d, I may try use the loom and coil from my 3ln to make sure the motor is good, but I hope to use the 2kr electrics if possible. Seeing as the 3ln tci doesn't fit the 2kr loom I can't use it to rule out the 2kr tci. I wonder if I can use 3ln coils on the 2kr? Pretty sure they are the same, only one way to find out if they do and if the silicone leads i pit on the 3ln coils work.
     
  6. Lynxdragon

    Lynxdragon Well-Known Member

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    Would you mind lifting your tank and just pulling gently on the 2 wires for the clutch switch and let me know what 2 they plug into on the 9pin plug? I know that the clutch safety switch bypasses the kill switch on the side stand, neutral combination safety. I'm hoping something is faulty there and the clutch may bypass it and fire a spark.
     
  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I only have a 2KR loom, coil's, tci and engine, my bike is a 3LN3.
    The ignition coil's measure the same 2kr and 3ln3, the standard plug lead's are solid copper core, so if your silicon lead's have resistance they may be dropping the power to the plug cap's
    What colour wire's come from the clutch switch ? and what colour is the plastic cover of the plug ?
     
  8. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Looking at my 2KR loom in the 9 pin plug, the blue w/black stripe wire and blue with w/stripe wire look to be coming from the clutch switch ?

    On the tci plug with the locking clip's to the top,
    the 6 terminal plug has a red w/white wire going to it (top row, 3rd terminal along), this should have 12v + with the ignition on.
    The grey (top row, left terminal) is the 12v + to coil's 2/3,
    the orange wire (bottom row, left terminal) below it is the 12v + to coil's 1/4

    If you don't have 12v + at the red w/white wire on the tci,
    as a test you could run a 12v + jumper lead from the battery + terminal to the red w/white wire on the tci, this should give you power to the 2x ignition coil's

    I think one of the 2x small 4 terminal relay's would be something to do with the 12v + power to the tci, possibly the clutch switch switch's the contact's in the relay to power up the tci?
    Could try swapping the 2x relay's around ? (hopefully they are both N/O or N/C ?)
     
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  9. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Last edited: Sep 6, 2017
  10. Lynxdragon

    Lynxdragon Well-Known Member

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    Okay soo ive double checked the power to the coils and TCI, all is good there is 12v. So im thinking now that if they all have power, then its probably the pulse coil. Good thing i have a spare one so will slam that into the bike and try it out.
     
  11. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    For what its worth, signal from TCI to coils should be pulsing 12v with engine running or starter enganged. Or at least thats how it was with the zeal. 2kr might be different but I doubt it. With just the ignition on I only got a reading of a few milli volts on either coil with a good TCI. With the bad TCI on the zeal, it was sending a constant 12 volts to the left coil which made it release the magic smoke. Caused by either the dodgy hotwiring or bad regulator killed the TCI.
     
  12. Lynxdragon

    Lynxdragon Well-Known Member

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    Alright so ive swapped the pulse and stator over, learned that the 3LN has the same pulse but the coil is physically larger. So pulled back the insulation so i could put the cover on with the coil hanging out the side of the bike. Still no spark, Swapped my test plug for a CR8EIX i had put asside for my 3LN project and still no spark.

    Regulator looks new, its all shiney and clean unlike the rest of the frame. Possibly scored a good one, or as Linkin said its already dead and killed the TCI.

    Looked at the wiring for my LH switch block, I seem to have a 6 Pin plug. I only have one blue wire, being a Blue w/black. So still hoping that its just the neutral safety circuit being dumb...

    Edit. Also swapped over the relays.
     
  13. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Check fuse box for blown or incorrect size fuses. My zeal had a 30 amp fuse in the ignition circuit (should be a 5 amp) which is likely what smoked the coil. After that the 5 amp kept blowing unless there was load on the electrical system (ie headlight on) - didn't click that it was the regulator that had gone bad. Very lucky it did not kill my new TCI box.

    Should be able to get a TCI from Japan via juace/buyee, just find the cheapest one as freight can be expensive.
     
  14. Lynxdragon

    Lynxdragon Well-Known Member

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    OMFG, OMFG **** sakes.... Broken earth to one of the relays..... Really..... Like, **** sakes....

    I have spark...
     
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  15. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    From what i have been able to work out looking at the circuit's, and testing my 3LN3 TCI and ignition-
    The red w/white stripe wire's going to the 2x ignition coil's supply 12v + to the coil's via the ignition switch.
    The orange and the grey wire's going back to the transistor's in the TCI from the ignition coil's are the one's that interupt the earth to the coil's, which collapses the primary coil winding and this cause's the secondary coil winding to spark
     
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  16. Lynxdragon

    Lynxdragon Well-Known Member

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    Bike started, Revved to like 6k then hangs and died... Not bad for a motor that has been sitting for 7 years. Going to put it into a drift trike now. Fun times!
     
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  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Vacuum leak ?
    Which relay had the broken earth ?
    I hope you're going to make a thread for that drift trike in the 250cc Project's area !
     
  18. Lynxdragon

    Lynxdragon Well-Known Member

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    Died at 6K because the carbs will be clogged up with god knows what, the fact that the exhaust was only bolted on from Cyl 1 and 4, and there was no airbox, sparkplugs are 2nd hand from services at my work, fuel is old as hell and was coming from an old scooter tank... Um... the engine was cold? Maybe no oil... Uh, Not a single **** was given on this day, Just needed to know the engine can make bike noises...

    Currently waiting for a mate to bring me the front end of his old 2KR so i can re-purpose the front end for the drift trike, Probably going to jam a scooter wheel on the front axle for a laugh.... Um, got a back end from an old trike fixed rear axle, disc brake and calipers still on it... hang on ill throw up some photos....

    [​IMG]
    [​IMG]

    Need to make some wheels from a go cart fit on those hubs, or put go cart hubs on it...
     
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  19. Lynxdragon

    Lynxdragon Well-Known Member

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    Yeh that poor little 2kr is hanging from a strop from the ceiling lol...
     
  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I have had similar thought's about my 2KR, but into my son's dune buggy (currently powered by a 110cc china horizontal full auto engine)
    Buggy has much bigger wheel's now and a few other mod's

    [​IMG]



    I saw this FZR250 powered buggy a while ago and it got me thinking...

     
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