Project Linkin's FZX250 Zeal

I fully agree.

Had a look at the front sprocket today. Appears the Zeals have the longer output shaft splines, same as the 3LN3+



However, it had a shim



And was installed like so

 

The dead coil warranted investigation. Found that it was getting 12v fed to it constantly. No wonder it let the smoke out... The other coil was only getting a few millivolts, as it should. Chucked a 3LN6 CDI on it, tested again, only a few millivolts to both coils now.



Now the starter circuit isn't working, probably because I ripped the ratshit wiring out. So waiting for the new harness to arrive.

Here's a few pics of the carbs. Clean on the inside, dirty filthy outside. Different needle setup to the 3LN1/3/5 and even the 3LN6/7

 

Got a few bits in the mail today. Wanted to do the brakes as well but too bloody wet and rainy. New mirrors, which fit and actually work. New indicators you can see in the background of the floor.



And I replaced the fuel tap, here's a pic of the old one. The original is missing the long plastic handle to turn it on or off, so I'll have to reach in under the tank now, as its not a vacuum operated one, just a standard job.

 

Did the brakes and the front brake lever. Old fluid was caramel soup or algae soup, take your pick. Replaced with Nulon Super Dot 4.





The front brake lever setup is a bit more complex than a standard or adjustable one, but it works. You have to take off the switch block and perch for the lever to get the old one off and the new one on. No photos of it, I'll get one later.

 

AliExpress to the rescue once more!

 

Where are my wiring loom & cdi, auspost?

 

Yeah, could be worse. Had a knock on the door, thought it was the postman, but no, just some more door knocker types, they've been relentless lately

 

Grrr.... "attempted delivery 4:32pm" my eye

 

Not the first time this has happened, usually get a card in the mailbox at least. The usual person shows up in the morning, generally. But nothing today, nada. And "attempted delivery at 4:32pm" appeared 45 minutes after that time had passed. On top of that, I paid for international express to my door, not the post office. Going to complain bigtime.

 

Finally got the harness and cdi. Measured voltages to the coils with the new cdi before plugging them in. All good, and pulsing correctly. Got the front blinkers fitted. Headlight, horn, blinkers, and spark all working correctly. All I'm left with now is an orange connector and a white with brown stripe connector, orange one has a pin but no wire. Now I am guessing, but I think there should be a wire for it. It would go up into the dash somewhere, but can't find any cut wires going up to the dash. I am missing the neutral light (could be a bulb, as the temp, high beam, and blinker lights work), and speedo/tacho backlighting. The speedo light never worked, but the tacho one did before the new harness.

I'm off to get some fuel to try and start it, any ideas about those 2 connectors?

 

It's alive!

 

This was found on the net, I've added it into th resources for the Zeal. Looks like my orange and white/brown are for the backlighting