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Help ZXR won`t start

Discussion in 'Kawasaki 250cc In-line 4's' started by TonyZXR, Apr 19, 2018.

  1. TonyZXR

    TonyZXR Well-Known Member

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    Ok so you might have seen my previous post about the bike breaking down on me. Tried to start the bike this morning with no luck . i can smell fuel so it must be electrical. Redid all the ignition leads . 2 had a bit of corrosion on them. Measured the coils which showed they were good . checked spark which it has . changed the ignition ecu still no luck . I`m stumped??
     
  2. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    flooded...if you can smell the fuel perhaps pull the plugs and let it dry out
    Other possibilities - leaking needle and seat valve flooded a cylinder, that could be the fuel you are smelling, in which case the oil will be laced with fuel, and could mean that you are out of fuel in the tank

    Hopefully someone with experience of the ZXR's can chime in with other ideas
     
  3. TonyZXR

    TonyZXR Well-Known Member

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    Well checked spark again . plugs are wet. doesn't seem to have a strong spark either
     
  4. Wozza

    Wozza Active Member

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    close your plug gap a little and see if it make a difference..if so its prob electrical
     
  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  6. sharky

    sharky Well-Known Member

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    You mentioned your reg/rectifier in an earlier post, have you checked the plugs not melted out?
     
  7. TonyZXR

    TonyZXR Well-Known Member

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  8. TonyZXR

    TonyZXR Well-Known Member

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    What`s the plug gap supposed to be ?
     
  9. TonyZXR

    TonyZXR Well-Known Member

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    Ahhhhh crapppppp.... Just checked it . It`s melted again.... Could that be the reason?
     
  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Highly likely, which pins are burnt on the plug?

    If its not one of the 3 stator phases, then its' possible you've boiled the battery with overcharging (regulator failure)
     
  11. TonyZXR

    TonyZXR Well-Known Member

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    Well it appears nearly all hahaha..actually looks like maybe a small fire. Battery is still fine . measures good voltage and isnt bulging.Mainly the white brown one of the yellows and a black wire are burnt

    20180419_173815.jpg
     
  12. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Yeah that's way worse than what mine did

    fVAYAAX.jpg

    I would start with a stator check. There is another plug underneath the airbox that you can use for the test.

    Your plug will have 3 yellow or black/red leads if using the lower connecter. Measure the resistance across all three of the leads and check against the spec in the service manual.

    For the AC voltage test we need the bike running and the reg/rec disconnected (with a fully charged battery)

    The last test is resistance from all three phases to earth (battery terminal or earth point on frame/engine) - anything under an infinite reading indicates a short.
     
  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Make sure the RR is earthing properly on the frame and that its not dirty ... should be spotless so the fins can cool it to the max

    Im guessing the A model has the same positioning of the RR as the C ... not enough air flow

    My C model burnt toast ...


    Burnt Toast.jpg
     
  14. TonyZXR

    TonyZXR Well-Known Member

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    A model is positioned even worse than the c. What airflow that does get to it is blocked off so it can`t get out . Also gave the plugs a good clean and gap . nice bright blue spark now but still no start ...even dumping a little fuel down the carbs doesn`t make it kick over . it just backfired out the exhaust once. Also the A model ignitor module wiring doesn`t have the sames colours as the c diagram
     
  15. TonyZXR

    TonyZXR Well-Known Member

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    Alright so i`ve measured the stator and i`m confident that it`s bad . measuring between the 2 outer wires it`s 0.6ohms which is in spec but measuring the inner wire with any of the outer wire shows 0.3 ohms so its out of spec. None of the wires are shorted to the frame . Measured the pickup coil and thats also within the right resistance which is 453ohms
     
  16. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    If you remeasured say 10 times and then averaged you're likely to even those readings out
     
  17. TonyZXR

    TonyZXR Well-Known Member

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    I did measure it 10 times haha got the same reading every time i also measured the other bike 10 times and that was always 0.6ohms across all 3
     
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  18. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Sounds like the stator may have shorted on that winding

    Take the stator cover off and visually inspect it, if it has insulation breaking down and dark discoloured spots then it needs replacing or rewinding (go to small coil rewinds)

    OEM stators are expensive but can be sourced, mx store on eBay have aftermarket ones for about $225 last I looked.


    You should also do a reg/reg test, just the part with the multimeter from the battery, but I'm confident it's gone.

    Aftermarket reg/recs... go with shindengen. Lots of modern BMW, triumph and jap bikes will use them. FH020AA is common. The SH847 is better but more expensive from roadstercycle.
     
  19. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I was hoping for you that it was just an erroneous reading - however on the upside you've found the source of one problem
     
  20. TonyZXR

    TonyZXR Well-Known Member

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    Yeah... I put a Chinese reg in it .Clearly wasn`t very good . The original reg wasn`t charging once it go hot . Worked on it a bit today . still no start just a few backfires . checked the cam timing which looks correct so no luck once again
     

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