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Help ZXR250C - Won't start! :(

Discussion in 'Kawasaki 250cc In-line 4's' started by JohnZXR, May 9, 2017.

  1. JohnZXR

    JohnZXR Member

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    Hi guys,

    I'm haveing issues getting my ZXR250C 1992 started. Bike has done 80,000k.

    It was running okay a few of weeks ago, Carbs weren't tuned so it wasn't perfect but it would start.
    Previously I had to use 3/4 choke and a little throttle to get started, from cold, occasionally it would take a few goes to get right, but would always start. When it was hot I had to use a little throttle only to get started.

    Starting a few weeks ago, I just haven't been able to get it started at all, no matter what variations of throttle/choke I've tried.
    Its turning over fine, I can hear its close to catching but just not quite getting there. I also hear a loud bang from the headers occasionally when I try to start it.

    So far I have replaced and checked,
    -New spark plugs (last ones were a little black but not too bad.)
    -All coils are producing a healthy spark
    -Rebuilt carbs with litetek seals (floats all set about 12.5mm and air/fuel screws at 2 3/4 turns out)
    -checked fuel is getting to the carbs all good.
    -no air leaks
    -Battery is still great.

    Also about 4 months ago I had a compression check and valves checked, which was all fine and within spec.

    Only recent changes with the bike are I changed oil/oil filter about 2 months ago and changed front sprocket to 13t a month ago.

    I would really appreciate any advice on what else I could check, I really miss riding!!!
     
  2. Frankster

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

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    Sounds electrical...like your KILL switch is on or there's a short somewhere. The C model won't start with the sidestand down (from memory). You've done all the right things with fuel supply, so I can only suggest electrical.
     
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  3. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Flick the kill switch a few times or take the switch block off and clean it with electrical contact cleaner. Put the bike in neutral, stand up, pull clutch to eliminate any of those circuits.

    Make sure the battery is fully charged.

    If no luck try a roll start... get going and into 2nd gear, as you release the clutch, bounce on the seat so the rear wheel doesn't skid from compression lock.
     
  4. sharky

    sharky Well-Known Member

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    Ive had them massive backfires through the exhaust & it wouldnt start, turned out to be the plug leads. They would show good spark when checking them over but were not firing properly when put back on the plug, all caused from the lead being broken off from the boot. Are your leads solidly attached to the boot or just pushed in? Just check your got the right leads to the right plug also.
     
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  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  6. JohnZXR

    JohnZXR Member

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    The starter motor is turning over fine so I don't think it could be the kill switch, ill take it off and give a good clean tomorrow just to double check!
    I always start bike with the clutch pulled in and kick stand up.

    Battery is fully charged, no problems there.

    Unfortunately Im not able to do a roll start where im located.

    Ive checked each spark plug lead gives a good spark with the plugs in against the engine.
    Ive made sure all the leads have clicked onto the spark plugs in the engine, all on the right number. Ill triple check all leads tomorrow just to be sure!

    Could the compression have dropped over the last 4 months?

    Thanks guys!
     
  7. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    My thoughts based on what you have said:

    **potential cause of loud bang**
    First off, like Sharky says the order you put your coil leads (if wrong) can cause mixture to ignite on an exhaust stroke which causes loud bangs but I presume you where facing problems starting before you started messing with the ignition?

    **What I think the route of the problem is**
    Another cause of "popping" when trying to start the bike (in my experience) is when the exhaust headers have become loose, not only will this exaggerate noises but also causes misfires/popping along with serious trouble starting!

    **Other possible things that could be exaggerating your problem**

    Idle speed screw - if this screw is turned too high you wont be able to start the bike, it would be like trying to start the bike with the accelerator at full throttle (the solution to this issue to to completely back the idle speed screw out *just dont back it out so far it falls out* and crack the accelerator just a pinch when trying to start

    Intake leaks - Apart from what I was saying above about exhaust leaks intake leaks can be troublesome, check the carb boots for leaks etc.

    Petrol contamination - If your tank has been contaminated with water it doesn't matter how clean your carbs are, try ditch the petrol and empty the carb float bowels and put some petrol in you know isnt contaminated.

    Oil level - Oil that is over full is bad, incorrect oil viscosity is bad etc etc get the oil right.

    Also check if a clutch start works.

    End
     
  8. JohnZXR

    JohnZXR Member

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  9. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    Good maintenance tip, but you said you had spark so id be looking elsewhere.
     
  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    So you were there in person to witness the quality and strength of the spark to make such an informative assumption?
     
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  11. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    note the disclaimer in the previous pose
    "My thoughts based on what you have said"
    I mean if we are just ignoring his hear say then I think he just lost his keys and there is a rat in cylinder 3.
     
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  12. kiffsta

    kiffsta Senior Member

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    fuel tap on ? vaccum line connected ?

    Carb boots okay ? sometimes they crack when pulling the carbs off.
     
    Last edited: May 9, 2017
  13. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Spark can test OK outside the cylinder and even on a spark gap tester, but still fail to work in combustion chamber conditions.
     
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  14. Joker

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

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    Hmm. You've tried testing for fuel to the carbies but what about fuel to the cylinder? I'm leaning towards fuel. Get an eye dropper and drip a few drops of fuel through the carbies directly into the cylinder (hold the slide up) and try again. If she fires almost starts you might have an issue in fuel flow somewhere, I know you said you rebuilt the carbies but you never know. Sometimes you gotta think root cause "what have I changed"? gets difficult when you change more than one thing I guess.
     
  15. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    Whaaada ya mean bad spelling! I was totally talking about my previous pose, I have a pose for every post I swear #model
     
  16. sharky

    sharky Well-Known Member

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    What I meant in my earlier post & something to check tomorrow, make sure the leads are attached securely to the boots(dont pull too hard), they shouldnt just easily pull out.Also, those boots actually screw down onto the plugs. Who done the comp' & valve clearances? With 80000ks on her hopefully not some dodgy on a Friday arvo.
     
  17. JohnZXR

    JohnZXR Member

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    Rechecked all spark plugs, all is good there. Had another go at trying to get it started and this is the best I got, so close to starting and when it finally did instantly died. Had it on 3/4 choke plus a tiny amount of throttle.

    When I have time later today, ill get fresh fuel and will try turning air/fuels screws out a bit more and go from there.

    Also worth noting that I haven't had any more loud bangs from the engine for a while now.
     
  18. Murdo

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

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    Definately try some fresh fuel
     
  19. Joker

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

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    What voltage are you getting from the battery? I've run a bike on fuel that is a year old and it worked fine.
     
  20. JohnZXR

    JohnZXR Member

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    Update: Still not starting unfortunately, Ive tried fresh fuel and adjusting the pilot screws out, As I said battery is great so definitely not the battery.
    Compression check was done by a reputable local motorcycle shop.
     
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