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Help get me home.

Discussion in 'Kawasaki 250cc In-line 4's' started by Adam Giles, Oct 14, 2016.

  1. Adam Giles

    Adam Giles Well-Known Member

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    Help, just got to work on a suddenly ill zxr250. Bike suddenly cut out while riding. Sudden stall so electrical not fuel.
    Pulled I'm clutch, started fine and away I went. Happened another couple of times until about 100 metres from work when it would cut out whenever I let clutch out.
    So if it's neutral, it runs fine clutch in or out, sidestand up or down.
    In gear it runs with clutch in, but not clutch out.
    My thought is that the sidestand switch is bad.
    However, I'm at work and don't have tools and stuff to hand.
    Question: easiest way to bodge cut out circuit to get me home?

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  2. Joker

    Joker See "about me" for contact details. Contributing Member

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    Sure your battery isn't cactus? Cutting out under load could have dropped a cell or two.
     
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  3. Adam Giles

    Adam Giles Well-Known Member

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    Starts and revs fine, let clutch out in gear and it cuts out.
    Not sure about anything really.

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  4. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Side stand switch circuit.
     
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  5. Adam Giles

    Adam Giles Well-Known Member

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    My thought. But I need a bodge to get me home. Can't leave bike here overnight, it won't be here in the morning.

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  6. kiffsta

    kiffsta Senior Member

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    ZXR250 has a male and female connector on the side stand switch, I would undo both wires from the loom, and plug the male to the female wire on the loom together which would effectively close the circuit

    adam.PNG
     
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  7. kiffsta

    kiffsta Senior Member

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    join the 2 from the loom like this to close the circuit

    loop.PNG
     
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  8. Adam Giles

    Adam Giles Well-Known Member

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    Cool, I'll look at that at lunchtime. Are the wires easy to get to?

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  9. kiffsta

    kiffsta Senior Member

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    not sure, I sold my ZXR, I really must buy another :thumb_ups:
     
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  10. Adam Giles

    Adam Giles Well-Known Member

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    I have zero access to tools until I get home...

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  11. kiffsta

    kiffsta Senior Member

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    Just check that your 2 Phillips head screws that hold the side stand switch to the side stand haven't come loose
     
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  12. Adam Giles

    Adam Giles Well-Known Member

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    That sounds likely, given the way it started and got steadily worse.

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  13. sharky

    sharky Well-Known Member

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    Hopefully it is only a loose sidestand, the switch is on the loom under the airbox you might be able to see it from the right hand side sitting on the clutch basket behind the frame, good luck
     
  14. Adam Giles

    Adam Giles Well-Known Member

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    OK, so sidestand and switch are secure. No chance of getting to wiring without pulling tank and airbox. Isn't going to happen at work.
    Had a quick play with switch and bike seems to working, but don't want to risk it cutting out on the motorway.
    My other thought was clutch switch. I can get to that. There are three cables. Do I need to short them all together? Would that fool system into thinking clutch lever was pulled in?

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  15. Adam Giles

    Adam Giles Well-Known Member

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    Update:
    Pulled clutch switch connector and shorted outside pins. Bike starter turns in gear and bike will run with clutch out and sidestand down. Hopefully this will get me home and can get a proper fix tomorrow.

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  16. Adam Giles

    Adam Giles Well-Known Member

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    Well, it got me home.

    [​IMG]

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  17. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Good use for a Paperclip..:)
    Almost McGuyver worthy...
     
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  18. Adam Giles

    Adam Giles Well-Known Member

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    Finally decided to get to the bottom of this. Pulled sidestand switch and cleaned and checked. Switch is good, but bike still doesn't run with clutch out. Checked wiring loom to junction box and tests good. Sidestand up and earth gets to junction box OK. My thinking is diode/solder in junction box is faulty. A model junction box is wired different so can't just swap to test.
    So, has anybody opened up the junction box before? Easy and safe?

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  19. Adam Giles

    Adam Giles Well-Known Member

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    P.S. bike still works fine with my paperclip fix.

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