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Help CDI trouble - ZXR250

Discussion in 'Kawasaki 250cc In-line 4's' started by Unkepttoenails, Oct 5, 2018.

  1. Unkepttoenails

    Unkepttoenails Demented

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    Hi guys I have an issue with my bike it is a c model frame but with an A model engine . I was wondering if anyone had some luck with figuring it all out as to what would need to be done to make out all work together . Is the solution to find a c lump and put it in or are there other options . I am pretty helpless when it comes to this so I am hoping someone here has had similar experiences and can shed some light on this for me .

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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  3. Unkepttoenails

    Unkepttoenails Demented

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    Thank you very much appreciated

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  4. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    If you're not a motorcycle mechanic or auto electrician, then your best bet is to find a working ZXR250A loom and TCI/Junction Box and replace the entire ZXR250C loom. From a wiring point of view, the two bikes are different. The engines are close other than carb main jets/needles. The ZXR250C Vacuum Valve and all of it's hosing are not used on the A engine/carbs, so you just need to make sure your carb vents are connected directly to the airbox. It would be far easier to find a C engine for your bike, but if you're committed to getting it going with the A engine, then there are plenty of folks on here who can help. There is a ZXR250A manual (Japanese) in the resources section of this website and some English converted material from that manual that will help you with your project. Good luck.
     
  5. Unkepttoenails

    Unkepttoenails Demented

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    @Frankster ,would you reckon the best bet is to go for the electrics end to get it to work ? Parts are so hard to get here in Ireland so I find myself not being about to get any parts you wouldn't happen to know any places closer to Europe that have parts for these bikes would you ?

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  6. TonyZXR

    TonyZXR Well-Known Member

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    The electrics should be fine in the c to run that engine . it`s only a crank pickup coil, alternator and few sensors . Shouldn`t be a reason to change the entire engine or wiring loom
     
  7. Unkepttoenails

    Unkepttoenails Demented

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    @TonyZXR would you happen to know exactly what would need to be changed to make it work proper ? As in would I need an a model pickup or a model c to work with the c Tci and harness
     
  8. TonyZXR

    TonyZXR Well-Known Member

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    cdi should match your harness . So if your bike still has your c wiring harness best bet would be to use the c tci because it'll plug straight in. Question is does it run ? or have you recently fitted the engine to the frame?
     
  9. Unkepttoenails

    Unkepttoenails Demented

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    I didn't put the engine in it was like this from a previous owner , I cannot get it to run right now but yes it is a c Tci and harness with what I am pretty sure is an a engine

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  10. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Okay, lets confirm it's an A engine first. There's an engine number stamped under the engine (see sample below). If it starts with ZX250A, then it's an A engine and we can try figuring out what's stopping it from running.

    Assuming yours is an A engine and it's plugged into a C loom/TCI etc, then we can get it to run (all things being equal). I run my drag bike with an A engine (and A carbs) and a C loom/TCI. It runs, but first chance I get I will go to an A Loom and TCI to match the engine/carbs to the TCI mapping for optimum performance. I'm 100% sure that there is power I'm missing (in the rev range) by using a C TCI. All electrical connection points are the same from A to C engines, so you don't need to change pickups etc. The C uses a sidestand lockout and the C headlights only come on when the engine starts.

    So, has your engine run in that bike or did you buy it as a non runner?

    What are the symptoms of the engine not running?

    Kawasaki Engine Number.jpg
     
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    Last edited: Oct 6, 2018
  11. Unkepttoenails

    Unkepttoenails Demented

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    Thank you @Frankster yes the engine is an a model and the Tci is a c as the numbers on it are for the c ( I can't remember off the top of my head ) so the bike will crank and cough like it is just about to start but never start for me other then the first time I try it it will start but then die as I have the idle backed all the way out to help it start

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  12. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Try turning the idle up to let more air in. Not too much as the engine will rev it's bits off if you open it too much.
     
  13. kiffsta

    kiffsta Senior Member

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    How are you starting it , best way is full
    Choke and no throttle, if it doesn’t start like that then pull the plugs and inspect them
     
  14. Unkepttoenails

    Unkepttoenails Demented

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    Kiffsta is that with the idle backed out all the way or open a bit like frankster said ?

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  15. Unkepttoenails

    Unkepttoenails Demented

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    Turns out one of the issue keeping it from starting was the choke cable was stretched and not pulling the assembly as it should so I will purchase a new one soon . It died under revs but I have a mechanic friend coming in the week to sort it out good for me . After I get it running I will begin finding the necessary parts to get the appropriate electrics so it runs as it should

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  16. ShaneP

    ShaneP Well-Known Member

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    What letter is on your tci igniter? J for 45hp, K is 40hp, from what I've seen.
    @Unkepttoenails sounds like carbies need sorting, definitely check your plugs, start with the easy and cheap options - though plugs are not easy, have to move the radiator, which means removing fairings, and it easier to do if you take the tank and airbox off
     
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  17. TonyZXR

    TonyZXR Well-Known Member

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    What about the M tci?
     
  18. ShaneP

    ShaneP Well-Known Member

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    Hmm. Maybe it is just a year, or Malaysian?
     
  19. Unkepttoenails

    Unkepttoenails Demented

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    @ShaneP that's pretty interesting to hear anyway glad you said that here it's good to have more information.
     
    Last edited: Oct 7, 2018
  20. Unkepttoenails

    Unkepttoenails Demented

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    @ShaneP I am not so experienced with all the mechanic work so I have a freind coming during the week to sort it out ,he's a bit of a guru when it comes to bikes so my best bet is him sorting it out
     
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