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Project Bought a ZXR250C.

Discussion in 'Your 250cc Projects' started by Linkin, Jan 30, 2017.

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  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Testing out the new camera, a contour roam 3. Got a few pics with it and recorded a cold/warm start of the bike. Pics have a bit of a fish eye effect to them but otherwise similar quality in low light to the trusty iphone 4s.

    bPgLZuP.jpg

    f8SlKUn.jpg

    O9BtX7a.jpg

    AyPw1Mo.jpg

    When starting the bike cold there are a lot less fluctuations of the revs, before it was all over the place. Haven't been able to get the sync checked again, but I'm hoping that will stop the rattle. Next on the list is the clutch, but I'm waiting on the springs to arrive - everything else is here. If neither of those sort it out, then I guess all that's left is the bearings in the motor, but I'm not so keen on splitting the motor just yet.



    As for the warm start, just a bump on the starter button and ZERO throttle :thumb_ups:

     

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    Last edited: Jul 15, 2017
    Linkin, Jul 15, 2017
    #101
  2. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Trying to figure out how to get this new reg/rec wired, bit of a headache because of the headlight coming on with the engine running, and I want to retain that feature. The roadstercycle instructions say I have to find the right wire and connect to one of wires coming from the stator.

    NcnrVRu.jpg

    U3TA5rI.png

    Fkb0NFy.png

    MOih7BN.png


    So my question here is what is the brown wire on the reg/rec for? On the testing diagram it's not listed, though the pin is there. The charging system diagram simply lists it as "load" - very descriptive. Still searching the manual for details...

    And connecting the brown to the yellow would seem like it would put AC voltage into the system?

    I hate electrical work.
     
    Linkin, Jul 24, 2017
    #102
  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    The brown wire is the trigger wire to start the reg/rect working, it need's to get 12v + when you turn the ignition on
    'The load is any 12v accessory's like light's, indicator's horn etc
    Same style reg/rect is used on a Yamaha Virago

    You can also fit a 5 terminal reg/rect and it'll work no problem's, the brown doesn't do anything on them
     
    my67xr, Jul 24, 2017
    #103
  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    OK that makes much more sense. New reg/rec is a 5 pin unit and should 'just work' once connected to stator and battery.

    I found that the headlight is controlled by the starter circuit as well, so I can tape off and ignore the brown, white and black/yellow. Too easy.
     
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    Linkin, Jul 24, 2017
    #104
  5. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Yeah, i'd just leave the brown wire in the plastic plug, it doesn't connect to anything so wont cause any problem's.
    And if you ever want to swap back to a 6 terminal reg/rect for any reason you just have to plug it in

    White is positive to the battery and ignition, Black w/yellow to negative and earth

    The brown wire is also sometime's called an exciter wire too, depending on who you talk to
     
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    my67xr, Jul 24, 2017
    #105
  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Time to talk about coil on plug conversions. The caps and leads on my ZXR are dodgy so I have constant misfires, and this is after trimming back the leads and cleaning up the caps.

    ZXR coil specs are as follows

    Primary resistance 2.3-3.5 ohms
    Secondary resistance 12 to 18 kilo-ohms

    The OEM Nichiwa plug caps have the following dimensions

    Overall length 105mm
    Cap seal diameter 25mm
    Length below cap seal 85mm

    I was thinking I could use Denso 127900-4400 coils like @my67xr did, but it appears they are too short - only 78mm long below the cap seal, unless I am mistaken. From reading your FZR250 thread those Denso coils have 1.5ohms on the primary, but they are run 2x2 in series which should be within spec for the ZXR as well.

    My main concern is that any new pencil coils I buy have to physically fit
     
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    Linkin, Aug 5, 2017
    #106
  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I've just taken a couple of pic's of my coil's for you
    I'll see if i can find the part number of the longer coil's and will post that up too


    The Nippondenso coil's part # 129700-4400

    measurement's are-

    From top of seal to bottom of lower seal/cap - 105mm
    20170806_085132.jpg

    From Taper of top seal to bottom of lower seal/cap - 95mm

    20170806_085155_001.jpg
    From top of taper to the bottom of the coil where the threaded part of your spark plug push's into - 78mm (hole in bottom of coil is 8mm deep)

    20170806_085728.jpg




    From top of coil where the seal sit's to the bottom of the coil is 84mm
    The shaft diameter of the coil is 22mm

    20170806_085844.jpg




    20170806_092221.jpg
     

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    my67xr, Aug 6, 2017
    #107
  8. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Here's a couple of longer coil's, you'll need to double check the spec's and length's though.
    Longer coil's -
    CBR1000RR Denso ignition coil's # 129700-4840 (1.5 Ohm's primary, 13.5 K Ohm's secondary)
    Z1000 Denso coil's # 129700-4580 (1.5 Ohm's primary)
     
    my67xr, Aug 6, 2017
    #108
  9. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    The 129700-4400's might fit if you used the original top seal off the Nichiwa caps?
    Top seal on the Denso cops is 25mm tall.
     
    my67xr, Aug 6, 2017
    #109
  10. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Thanks for the dimensions. @Adam Giles have you got a standard ZXR plug cap lying around you can measure up?
     
    Linkin, Aug 6, 2017
    #110
  11. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    @sharky posted the specs somewhere i think?
     
    my67xr, Aug 6, 2017
    #111
  12. sharky

    sharky Well-Known Member

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    Heres a plug I sacrificed awhile ago to check out whats in there, 20170806_122816.jpg I had a win by trimming the leads and screwed the fresh wire down onto that gold screw until it was set on the thread.
     
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    sharky, Aug 6, 2017
    #112
  13. sharky

    sharky Well-Known Member

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    20170806_124128.jpg 20170806_124352.jpg 20170806_124226.jpg 20170806_124539.jpg
     
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    sharky, Aug 6, 2017
    #113
  14. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    OK, looking good so far. The total length of both caps, from the top of the spark plug seal, is 84mm. The deciding factor now is how far the spark plugs themselves sit in the ends of the caps - so how deep is the recess in the OEM cap and the denso coil?

    Alternatively, put a spark plug in each one and measure the total length of from the top of the cap seal, to the end of the spark plug
     
    Linkin, Aug 6, 2017
    #114
  15. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    my67xr, Aug 6, 2017
    #115
  16. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Linkin, Aug 6, 2017
    #116
  17. sharky

    sharky Well-Known Member

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    Plugs (cr9e) are 70mm long and when screwed down correctly have 35mm protruding if thats the measurement you were after? 20170806_133823.jpg 20170806_140454.jpg 20170806_134812.jpg
     
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    sharky, Aug 6, 2017
    #117
  18. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Yeah that last measurement is what I was chasing, thanks mate. @my67xr have you got a plug lying around to check against your 4400 coil?
     
    Linkin, Aug 6, 2017
    #118
  19. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Measured the Denso coil's with a CR8E plug fitted
    120mm from the end of the plug goes to the first ridge on the rubber seal, so look's like you could slide the rubber's down and use a grommet on top to make it seal to the rocker cover

    Total length of the 127900-4400 Coil and plug is 165mm


    The longer coil's will need you to make up a seal for the top's
    The total length of the 127900-4840 coil and plug will be 190mm

    20170806_141950.jpg
     
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    my67xr, Aug 6, 2017
    #119
  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    For the wiring etc i used a length of loom from a BA Falcon/Territory, there is enough length in the factory loom to cut the extra length of wiring back
    Same coil connector's are used on Mazda's and Holden's and a lot of other car's
    Could have got those socket/terminal's locally, pretty sure Autobahn sell them individually probably other part's shop's too
    http://www.ebay.com.au/itm/Set-of-6...426636?hash=item2ef4ac46cc:g:0kcAAOSw9IpX0gcc
     
    my67xr, Aug 6, 2017
    #120
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