ninjette.org - View Single Post - pushing bike in 2nd clutch out seized engine?

DannoXYZ · April 30th, 2019, 02:02 AM

Nope, not stupid or wrong, just inexperienced. Which is where we come in. OK, we need to separate your issues into multiple items with different troubleshooting procedures. You’ll need the following:

- official 2008-12 Ninja 250 workshop manual, search around for one
- smart battery charger
- multimeter

BATTERY
Even with a jumper pack, each time you crank, it will drain battery. So very first thing you do is put battery on charger until it’s fully charged to 13.8v. This should drop to 12.6v after resting for couple hours. There are no sounds of any sort when you turn key ON. Even headlights will not turn on until engine is running.

FUSES
Pull each and every fuse, including 30a main fuse on starter solenoid and measure resistance across their legs. Post your measurements here.

INTERLOCK SWITCHES
How did you bypass kickstand switch? Read up on how the interlock switches work here: https://faq.ninja250.org/wiki/Unders...afety_switches

Replace broken clutch lever, it may not be activating clutch switch properly. Measure resistance of all interlock switches and post results here.

Also measure for voltage on power side of starter circuit as shown in guide. Do you have 12v power at every stage? Including 12v at activation terminal of starter solenoid?

ENGINE SEIZED?
You’ll want to limit amount and weight of parts being moved.

1. Put gearbox into neutral
2. remove both spark plugs
3. Locate stator/flywheel cover on left side of engine.

4. Use a 45mm washer with pliers on slot in middle of cover to unscrew centre cover

5. Use socket wrench on flywheel bolt visible in centre of stator cover

6. Gently spin engine anti-clockwise through 360-degrees rotation. If engine spins, it’s not seized.

PETCOCK TEST
1. Remove larger petcock hose from carburetor inlet (be careful not to lose little filter INSIDE hose. Note its orientation so you can reinstall.

2. Turn petcock to PRI position, does fuel flow?

3. Turn petcock to ON pisition, no fuel should flow.

4. Disconnect vacuum hose coming out of petcock from where it plugs into carbs. Apply vacuum to this hose. Does fuel flow from larger fuel hose?

After you’ve gotten all wiring fixed up and ensured engine’s not seized, you may still have gummed up and clogged carbs. That’s covered in another chapter....

April 30th, 2019, 02:02 AM	#3
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Nope, not stupid or wrong, just inexperienced. Which is where we come in. OK, we need to separate your issues into multiple items with different troubleshooting procedures. You’ll need the following: - official 2008-12 Ninja 250 workshop manual, search around for one - smart battery charger - multimeter BATTERY Even with a jumper pack, each time you crank, it will drain battery. So very first thing you do is put battery on charger until it’s fully charged to 13.8v. This should drop to 12.6v after resting for couple hours. There are no sounds of any sort when you turn key ON. Even headlights will not turn on until engine is running. FUSES Pull each and every fuse, including 30a main fuse on starter solenoid and measure resistance across their legs. Post your measurements here. INTERLOCK SWITCHES How did you bypass kickstand switch? Read up on how the interlock switches work here: https://faq.ninja250.org/wiki/Unders...afety_switches Replace broken clutch lever, it may not be activating clutch switch properly. Measure resistance of all interlock switches and post results here. Also measure for voltage on power side of starter circuit as shown in guide. Do you have 12v power at every stage? Including 12v at activation terminal of starter solenoid? ENGINE SEIZED? You’ll want to limit amount and weight of parts being moved. 1. Put gearbox into neutral 2. remove both spark plugs 3. Locate stator/flywheel cover on left side of engine. 4. Use a 45mm washer with pliers on slot in middle of cover to unscrew centre cover 5. Use socket wrench on flywheel bolt visible in centre of stator cover 6. Gently spin engine anti-clockwise through 360-degrees rotation. If engine spins, it’s not seized. PETCOCK TEST 1. Remove larger petcock hose from carburetor inlet (be careful not to lose little filter INSIDE hose. Note its orientation so you can reinstall. 2. Turn petcock to PRI position, does fuel flow? 3. Turn petcock to ON pisition, no fuel should flow. 4. Disconnect vacuum hose coming out of petcock from where it plugs into carbs. Apply vacuum to this hose. Does fuel flow from larger fuel hose? After you’ve gotten all wiring fixed up and ensured engine’s not seized, you may still have gummed up and clogged carbs. That’s covered in another chapter....
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