ZZR-250 Ignition Problems

Hi All

Fitted the new ignition switch to the ZZR and got headlights, instrument
lights etc. but no spark.

Side stand was up, clutch was pulled in. Starter spins but no spark at
either plug.

Apart from "swap bits around from another bike", any ideas where to
start testing?


I'm no electrical genius but I know my way around a multi meter. Tried
all the online resources I could find and they get as far as "Could be
IC Ignitor problems" but no further details.

Only thing I can think of is that when these little arseholes tried to
steal it, jamming the screwdriver so far into the ignition switch
screwed up the electrics and cause some sort of short into the coils or
ignitor. However I can't see (from the wiring diagrams) how this could
have happened.

TIA for any suggestions (short of taxidermy)

Nigel.

 

Kill switch?

Boxer

 

Boxer is of the opinion:

From memory, it doesn't turn over unless the kill switch is set
appropriately. The 600 certainly doesn't (just went out to the shed to test
it). It's worth bearing in mind though, Nigel, since it only takes a
half-second to check, and can save much swearing. <grin>

- Matt

 

Nigel Allen is of the opinion:

It could be that, or coils, or a dodgy earth, or a bunch of other things.
Electrical problems suck. The workshop manual will have a full procedure
for diagnosing problems like this -- things like "the resistance between
pins X and Y of harness foo should be N ohms this way and M ohms the other
way". It takes a while, but it will answer the question definitively one
way or another. Double-checking the simple stuff, like kill switch (as per
Boxer's comment) and fuses is worthwhile before going hell-for-leather with
the multimeter.

I've never seen inside an ignition barrel, but I have my doubts that that's
a possibility.

- Matt

 

I *think* it should crank over in neutral even with the sidestand down
and clutch out. If it cranks it should be sparking, unlike many older
Hondas the starter won't crank over a Kwak of that vintage while the
kill switch is off.

That's pretty unlikely. Since both coils are non-functional I'd be
suspicious that the CDI is unplugged, or some vital wire to it has
been broken or disconnected elsewhere. If they failed on the
screwdriver-in-lock they might have though that they could hotwire it
- was there any damage to the wiring harness?

Also, is the new lock from a ZZR250 or "something similar"?


BTH

 

Not that we could see - the main damage was to the ignition lock and
wiring to the same. I'll take another look but all the plastic was still
in place so it's unlikely.

I also read in an article that you have to be very careful testing IC
(as opposed to CDI) ignition - putting power on the coils for too long
can cook them. Given that the ignition fuse was blown I'm starting to
smell a new IC Ignitor on the horizon.

Nah - thought of that - it was from a "real" ZZR.

I've got a friend looking at it at the moment - he's a sparky by trade -
albeit a domestic type sparky - but has a long bike history and used to
do his own spanners when he competed.

I've also got an ER-5 sitting here so we're contemplating swapping a few
bits around to see if we can get anywhere before we throw it in a van
and take it to Motorcycle Weaponry in Mona Vale.

Really starting to sh*t me.

N/