Project Linkin's FZX250 Zeal

So the R6 is gone, unfortunately, but sometimes life throws you a curveball. I had fun with that bike...

Picked this up from Newcastle area today. At first glance, it needs a fair bit. Ignition barrel, battery, leaky fork seal, busted fuel tank cap, no mirrors, the rider seat locating tab has been sawed off, the tachometer housing is busted. Radiator is hanging off, tyres are cactus, and so on. Fuel tank is rough on the exterior, but OK inside. Fork bottoms have had the salt air get to them. Horn has been cut off, front disc is covered in fork oil... Lots of little things.

At a glance it would look like it was stolen, but the VIN came up clean, so maybe it was stolen and never reported while also unregistered. Who knows...

I think they are a good looking bike, and best of all, they use that FZR250 engine with different cams & cdi. 15k RPM redline. Clean up the rust and grime and it should look really good.

 

Only by a miracle! Just about everything needs attention.

The radiator mount tab is busted, so either needs to be repaired or replaced. I got the fizzer ignition barrel in, it fits & the steering lock works, too. Someone has definitely pinched this bike in the past though... Hacked wiring and crap electrickery to get it going.







The Rhino Seal Doctor, as recommended by Dr. Murdo, does actually work! I used on the R6 and it seems to have done the trick here as well. You lift up the dust seal, wipe all the crap away, put the thing on the fork & slide it under the seal. Spin it around and lift up. Gets all the crap stuck in the seal out, and stops it leaking.







She has the electron juice flowing, but still no worky worky... One of the coils started to let the magic smoke out, so it's probably toast. Good thing the fizzer ones are the same, as I still have a frame with spare bits under the house.

I think I'll just order a replacement wiring harness from Japan, along with the other crucial bits, I am loathe to fix wiring issues.

 

Ridden plenty of fizzers, but not any zeals.

Had another go at the electrickery. Found some fuses in the wrong spots, corrected those. Have the tacho backlight working, nothing on the speedo, still no lights. Doesn't turn over now, just lights up the oil/temp light when you press the starter.

I f&#%ing hate hack jobs!

 

Different sub harness for the headlights/dash etc.

 

Nothing for the Zeal. But a 2nd hand harness from the wrecker, or a new one from Japan, shouldn't be too much.

 

Perhaps. An english manual would be nice.

I just used buyee for the first time, scored a complete wiring harness for 50 bucks. The wreckers in oz want 100 to 150 bucks for one! They're dreaming...

 

OK so the bike blew the 5amp fuse on the ingition/starting circuit. Shorted the solenoid and she cranks. Tried a 15amp fuse and it cranks, but there's no spark on either coil. I think it had 20a or 30a fuse in the ingition circuit initially and the coils let the smoke out, so I'd say that's why there's no spark.

Not gonna risk letting the smoke out of my spare fizzer coils, so will wait for the wiring harness to get here before trying th electrics again.

 

This coil is toast for sure... can't find my spare 3LN ones anywhere



And is probably the result of this shite






So, undid all the gooey duct tape, ripped the shite out, and this is what we're left with...


Cut brown wire from harness



Orange bullet connector with no matching bullet



This guy from the harness



Connected to cut brown wire/bullet connector, wasn't connected to cut brown wire from the harness



And this, the thick insulated part was hanging out of the headlight. Brown and black wires.

 

Nice, I'll drop by later...

 

Yeah, not impressed.

Yeah I think so!

Surprisingly, the other coil tested OK when compared to the spares from the fizzer factory spares bin. 15k ohms between the two spark plug leads (with the caps off) and 2.5-3 ohms between the harness connectors. The cracked one was open circuit/no resistance