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Help FZX250 Zeal Spark Issues

Discussion in 'Yamaha 250cc In-Line 4's' started by Jimcr22, Sep 19, 2018.

  1. Jimcr22

    Jimcr22 Member

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    Hi All,

    So this is my first time posting on here. I bought a Yamaha FZX250 Zeal about 6 weeks ago now because I liked the look of the bike and got it really cheap. The bike is now having spark issues and wont run. The bike originally didn't run well, but I was confident that I could resolve the issue as it was just a carburettor issue.

    So the story goes, I bought the bike. Got it home pulled the carbs off and found that whoever had worked on the bike before had not tightened the jest in the carburettors when they had worked on it so they simply fell out into the carbs. This was an easy fix and the bike ran better after this.

    To try and improve the running after that, as it was still only running on 3 Cyl at idol I pulled off the rocker cover to check valve timings and clearances. I also had to take off the alternator to align the engine to TDC. Not finding any issues I replaced everything and then tried to start it. Then it wouldn't start.

    I checked a lot of things and found that there was only a spark on Number 2 Cyl. there was a very weak spark on the other cylinders but barely enough to see and not enough to actually fire. Thinking that I had caused an issue with the ECU I got a new one for a decent price and replaced it. This didn't change anything.

    I tried swapping the ignition coils next and testing them. Both coils have 12v supply voltage and when I swapped them over and checked the spark I got exactly the same issue.

    Next I thought that it might be the ignition lockout relay box that was causing the issue, so i sourced one of them and replaced that. Again no change, still just firing on Cyl No 2 and would not run.

    Then I thought maybe it was the pulse pickup coil in the alternator housing. So I measured this, I was getting 130 ohm resistance (specs on for this coil are 230 ohm) and 1.3-1.4V output when cranking. Not sure if this is correct because there are no measurements for this online. So thinking this was the cause I replaced that too.

    Now I have gotten to the point where I don't know what else to do. Nothing I do seems to have any affect and I have replaced almost the entire ignition system. The Spark plugs are also only about 2k kms old.

    I have also charged the battery, thinking maybe it was simply low battery voltage but the battery is new and that also had no effect on it.

    Does anyone have any ideas of what I can do next because I am lost now? I have run out of ideas and things to replace.
     
  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Welcome to the forum,

    I would be testing the primary and secondary resistance on the ignition coil's
    You'll need to unscrew the spark plug cap's off each lead to do the latter.
    Also check the resistance through each spark plug cap while you're there, they shoulkd read 10K Ohm's (10,000 Ohm's)
    They can have higher or lower resistance due to corrosion inside the cap's, unscrew the end inside and pull them apart, don't lose the spring resistor or washer if you can help it.
    Use some dielectric grease on them to help avoid corrosion.

    This thread help's explain how to test the ignition coil's with a multimeter
    https://www.2fiftycc.com/index.php?threads/multimeter-coil-test-–-twin-lead-coils.9510/

    And if your spark plug lead's are long enough trim 10mm off the end of each lead for the spark plug cap's to screw into so it's all fresh

    Lastly do you have fresh, new spark plug's fitted ? sorry just saw the spark plug's aren't that old
     
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    Last edited: Sep 19, 2018
  3. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Hey Jim,

    Might be as simple of the coil leads are a bit worn where the cap screws onto it, first off set your multimeter to ohms and test plug cap to plug cap on each coil and post your results. I would un-screw the coil cap and perform a ohms test from each end of the cap and post your results, while the cap is off the lead, use some side cutters and trim about 5mm off your plug lead and rethread the spark plug cap back on. Do the first ohms again testing cap to cap and see if your results improve. I see it time and time again where people grab the lead instead of the cap when changing the plugs and it pulls the lead away from cap resulting in weak spark.

    If your pulse coil is working, your CDI is working and you have 12v at the coils, could be as simple as the coil leads needing attention.

    Good luck

    Chris
     
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  4. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Have a look near the end of this first thread below for discussion on coils and plug caps etc ... Zeal is really just a detuned FZR motor .. I would use brand new plugs when everything else is done/sorted

    https://www.2fiftycc.com/index.php?threads/help-required-please-fzr250.10045/page-3

    https://www.2fiftycc.com/index.php?threads/trim-your-spark-leads.8032/

    https://www.2fiftycc.com/index.php?...eads-spark-plug-configuration-inline-4s.8176/

    https://www.2fiftycc.com/index.php?threads/fzr250-coils.10134/
     
    Last edited: Sep 19, 2018
  5. Jimcr22

    Jimcr22 Member

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    Thanks for all the input guys, I will investigate the plug leads and coils that and get back to you.

    The main thing that sticks in my had is that it ran up until the point where I removed the rocker cover and checked the timing. After that I have had all this issue.

    Does anyone know what the output voltage of the pulsar coil should be? I am only getting up to 1.3v max.
     
  6. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Have you got the right firing order?
    You would have removed the leads to get the cover off, so did they go back on right plugs?
     
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  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Pulse coil should be reading between 184 Ohm's and 276 Ohm's depending on the temperature it's measured at
     
  8. Tigger996

    Tigger996 Active Member

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  9. Jimcr22

    Jimcr22 Member

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    Hi Guys,

    Sorry for the late reply on this one but I finally got it worked out. I cant believe this but it ended up being the spark plugs. All of them failed at the same time.

    Thanks for the help. Now I just need to tune the carbs...
     
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  10. ruckusman

    ruckusman Well-Known Member Premium Member Dirty Wheel Club

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    Just read this thread, and as I was reading your initial post I was just saying to myself 'just change the plugs' - they're likely shorting due to a carbon build up'

    And then you did and got it sorted.

    I do applaud you for coming back and sharing that the plugs were the solution, and if you thought that was a pain, you're now onto the carbs - thankfully we're all knowledgeable about carbs round here, because its been a long road
     
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