I have an FZR250 3LN 1989 which has some known problems. It needs a new indicator relay and what was described as a power relay (possibly the ignition cut off relay as there is no spark). The problem is that the manual does not show the location of the relays and trying to match relays with the colour coded wiring is not helping. Any help would be appreciated. Also I would like to fit a solo seat but google can't find any. What other model solo seats would be easiest to modify. Thanks
The indicator relay/flasher can is the one at the back (below the rear glove compartment lock), it's a 2 pin flasher can, the main relay must be the one to the left of the flasher can
Replaced the relays and the loom, but I have one wire on the loom that I cannot find a place to connect it. The wire is located in the clump behind the headstock near the coil connectors and is RED&GREEN. My wiring diagram doesn't show that colour combination anywhere, anyone know where it goes please. Every thing works except still no spark.
Is it possible you might have a Zeal FZX250 loom? they use a red w/green stripe wire for the temp indicator light (high temp/overheated) on the dash. I cant remember any single red w/green wires on my FZR250 3LN3, but will have a look next time the tank is off. Do you have 12v + going to the ignition coils when the ignition key is turned on, kill switch on run ? New spark plugs in it? Does it crank over when you hit the start button?
Thanks for the replies. Not an earth as it has a bullet connector. Not a Zeal. It is a 1989 3LN1. The replacement loom is the same (without corrosion) as the one I removed(yes I should have looked closer when I disconnected it). I will check the power to the coils. I will fit new plugs when I get a spark. When I bought the bike it had been a runner that was unused for a couple of years and corrosion had started in the loom connectors and some bodged wiring
I stripped out the old loom and followed the red/green wire to the six pin plug on the headlight unit, but I still don't know what it does. Should the coils have power when the ignition is switched on (like my Ducatis) or only when the engine is running?
Do you have a picture of it ? Trying to work out where you're looking, i have my tank off atm so might be able to help Coil's are powered when the ignition key is on, and kill switch is in the run position The red w/white stripe wire's to the coil's should show the same voltage as your battery, or close to it
I think my67xr is probably correct that it is the temp indicator light, but I cannot find anywhere to connect it. I will check the feed to the coils again (at the coils and the kill switch) Thanks again
You need a Zeal (FZX250) dash to connect it to, the FZX250 main loom is basically the same as the 3LN1 loom. i wouldn't be too worried leaving it unattached, just tape the end over FZR400 had a green w/red stripe wire on one of their model's too, it was for the reserve tank function ? May be a translation issue ^ Your bike doesn't have EXUP does it ? Definately no red w/green stripe single wire on the 3LN3
Yes it s an EXUP. Borrowed a multimeter. 12volts at both coils. I have ordered a replacement digital igniter unit Voltage recorded on the red/green wire and when I earthed it the temperature gauge went off the scale. After much searching I found the sensor unit and plugged it in, mystery solved. Just hope the digital igniter unit will solve the missing spark.
That red wire w/green stripe must be a green wire w/red stripe if it's for the temp sender below the fan switch on the thermostat housing.
If you have 12 volts at the coils with ignition on then you should have spark. The way TCI works is that the field, ie your 12 volt supply to the coils, is collapsed (grounded) which provides the spark. Your pickup coil tells the TCI when the crank is at top dead centre, and the TCI has the ignition advance curve programmed into it. Your tachometer signal plays a part as well. There are no relays in this system that I know of. If you don't have spark, you need to check that all those components are working. Start with the caps, HT leads and work backwards from there.
There'd be relays in the TCI to switch the earths to the coils. They would be little surface mount relays not like the bigger relays used for fuel pumps and lights etc. Check.the coil Ohms, primary should be 2.4 - 3 Ohms (meter set to 200 Ohms), secondary readings should be 12K - 16K Ohms (meter on 20K Ohms) with spark plug caps unscrewed from the end of the leads. I might list the Ohm's readings from my 3LN3 TCI so people have something to compare theirs to. I've already done that with a 2KR TCI. If you have an old analogue multimeter you could check the Darlington transistors are turning off in the TCI to fire the ignition coils. Set the multimeter to 20 volts dc and put the red lead from your multimeter to the black wire at the coil, and the black lead from the meter to earth. The voltage should momentarily drop from 12v to 0 for a millisecond as you crank it over.
Found this pdf which others might find useful. http://rg500delta.com/RG500_chassis_files/master cyl bore sizes.pdf But it shows the 3ln1 as 5/8" bore whereas my master cylinder has 14 cast on it. Have I got a non original one as I will have to change it soon due to a stripped thread that was badly helicoiled.
I gave up on the lost spark and took it to a Yamaha dealer. It was the lead joining the loom to the generator coil.
