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Old January 11th, 2019, 12:07 PM   #1
JackTheAlbatross
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New 250 owner Troubleshooting Questions

Hey, guys! I've been visiting these forums (and faq.ninja) for about a year now while fixing up my 2006 Ninja 250r I got from a friend. I gotta say you've all been a lot of help!

My bike hasn't run for about 2 years as my buddy wrecked it and bent the fork.
So far I've:
Replaced the front fork assembly.
Drained the gas tank (now has new fuel)
Installed new battery (All elec components are doing what they should)
Installed new spark plugs (kept old ones)

But I can't seem to get the bike to turn over. The only thing I haven't done is clean out the carburetor because it looks like a pretty big job for a novice. Funny thing is, when I go to crank the bike up, if I spray starter fluid into the air intake, the bike begins to turn over(but only with the clutch fully engaged). But if I let go of the ignition switch, it wont idle.

My biggest problem is that troubleshooting this way drains the battery. I'm having to use a trickle charger to charge the battery every time and I don't want to screw this brand new battery up. I've read on reddit that you can hook up a car battery to the brake lever and use the car battery to eliminate that issue. But I can't seem to find any information on this. Any suggestions?

(I've also bought Seafoam carb cleaner but I haven't used it yet haha)
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Old January 11th, 2019, 12:22 PM   #2
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For a bike that hasn't been running for 2 years, it's gonna need those carbs to be rebuilt.
Either send them out to be cleaned and rebuilt or chance them yourself as a learning experience.
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Old January 11th, 2019, 01:57 PM   #3
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Quote:
Originally Posted by JackTheAlbatross View Post
My bike hasn't run for about 2 years as my buddy wrecked it and bent the fork.
So far I've:
Replaced the front fork assembly.
Drained the gas tank (now has new fuel)
Installed new battery (All elec components are doing what they should)
Installed new spark plugs (kept old ones)

But I can't seem to get the bike to turn over. The only thing I haven't done is clean out the carburetor because it looks like a pretty big job for a novice. Funny thing is, when I go to crank the bike up, if I spray starter fluid into the air intake, the bike begins to turn over(but only with the clutch fully engaged). But if I let go of the ignition switch, it wont idle.
Most likely you have carb work in your future.

Look through this section, especially the info on carb removal and cleaning - https://faq.ninja250.org/wiki/Intake

You need to do it carefully and meticulously, or you'll be doing it again.

If you want it done professionally (and right the first time) look up ducatiman here.
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Old January 11th, 2019, 04:08 PM   #4
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Quote:
Originally Posted by Ceeloo Yello View Post
For a bike that hasn't been running for 2 years, it's gonna need those carbs to be rebuilt.
Either send them out to be cleaned and rebuilt or chance them yourself as a learning experience.
Thanks! I guess I'll just have to finally bite the bullet and do it.


Quote:
Originally Posted by jkv45 View Post
Most likely you have carb work in your future.

Look through this section, especially the info on carb removal and cleaning - https://faq.ninja250.org/wiki/Intake

You need to do it carefully and meticulously, or you'll be doing it again.

If you want it done professionally (and right the first time) look up ducatiman here.
Haha I actually ran into an old man in Walmart today while shopping for starter fluid and he told me the exact same thing. I'll contact ducatiman if I don't feel up for the job.

Thanks.
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Old January 11th, 2019, 04:08 PM   #5
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Welcome!

My hubby had a bike that hadn't run for a while, and it needed the carbs cleaned and redone.
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Old January 11th, 2019, 08:05 PM   #6
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Originally Posted by CaliGrrl View Post
Welcome!

My hubby had a bike that hadn't run for a while, and it needed the carbs cleaned and redone.
Thanks! My bike is the exact same as the one in your profile pic. Can't wait to get it running.
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Old January 11th, 2019, 08:33 PM   #7
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Good luck! Check on some of the past threads on rehabbing hibernated bikes. Is a good bike and you'll have a good time once you get her running.
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Old January 13th, 2019, 08:35 AM   #8
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I'm fairly mechanically competent, I've resurrected several Ninja 250's. I thought I knew what I was doing with their carbs until I sent a set to Ducatiman.

Save yourself a lot of frustration and just contact him.
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Old January 24th, 2019, 08:13 PM   #9
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I'm fairly mechanically competent, I've resurrected several Ninja 250's. I thought I knew what I was doing with their carbs until I sent a set to Ducatiman.

Save yourself a lot of frustration and just contact him.
+1 - I too thought that I did a good job of cleaning several sets of carbs - until Ducatiman did a set for me!
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Old January 26th, 2019, 01:16 PM   #10
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thanks gents for positive comments!
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Old February 3rd, 2019, 01:46 PM   #11
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Hey, guys! Quick update: I sent my carbs to Ducatiman and got them back really quickly! The guy's some sort of magician. Here's Ducantiman's thread showing the before and after. https://www.ninjette.org/forums/showthread.php?t=330041

Thank you guys so much for point me towards him! The guy's saint and his enthusiasm for what he does is contagious.

I've tried to start it once I finally got the air intake boots to slip over the carburetor. (Seriously, this took more effort than I'd like to admit. I gave up on it earlier this week and woke up the next day with muscle aches. Haha)

The good news is that it'll turn over now(choke fully engaged only)! But it won't idle for too long. Three seconds after it turns over, it dies. I got a bit of smoke from the tail pipes once but afterwards none at all.

Any suggestions on what to do next?
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Old February 3rd, 2019, 03:05 PM   #12
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to begin with, turn the idle adjuster up a bit, try it with less choke (maybe 1/2)

got fresh fuel in there?
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Old February 3rd, 2019, 03:36 PM   #13
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Quote:
Originally Posted by ducatiman View Post
to begin with, turn the idle adjuster up a bit, try it with less choke (maybe 1/2)

got fresh fuel in there?
Hmm.. I'll try that.

Fuel is from maybe late December when I derusted and cleaned out the gas tank. Should I drain it out and fill it with fresh gas again?
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Old February 5th, 2019, 10:08 PM   #14
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You most likely have petcock issues. It may be clogged with rust. Its diaphragm may not hold vacuum to keep fuel flowing.

Last futzed with by DannoXYZ; February 6th, 2019 at 08:05 AM.
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Old February 7th, 2019, 11:51 AM   #15
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Originally Posted by DannoXYZ View Post
You most likely have petcock issues. It may be clogged with rust. Its diaphragm may not hold vacuum to keep fuel flowing.
Thanks! Attempted to get the petcock off to clean it. But seems like one of the nuts is seized into the tank. I keep turning the nut and it doesn't move in either direction.

Looking through forum posts on other sites, seems like I might have to get a brand new tank..?

What do you guys think?
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Old February 7th, 2019, 12:04 PM   #16
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Originally Posted by JackTheAlbatross View Post
Thanks! Attempted to get the petcock off to clean it. But seems like one of the nuts is seized into the tank. I keep turning the nut and it doesn't move in either direction.

Looking through forum posts on other sites, seems like I might have to get a brand new tank..?

What do you guys think?
It's spinning but not coming out?

Try getting something under the bolt head, or the petcock where it mounts, to apply pressure outward as you spin it.
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Old February 7th, 2019, 12:27 PM   #17
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Bolts, not nuts that hold the petcock to the tank, no?

10mm head, no? .....counter clockwise ONLY to loosen, get some PB blaster on it.

Any way you can invite an experienced mechanical type neighbor, relative or friend over for an assist?

Put out a call on the ninjette forum for a local, nearby member? We'd get it in 3 minutes (or less) if we were locals.
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Old February 7th, 2019, 12:32 PM   #18
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just occurs to me, Jack...have you TESTED the petcock for flow under vacuum conditions as yet?

If it IS delivering, may be pointless in removing and screwing around with it.

TEST FIRST says I. Confirm its pooched before getting in over your head.
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Old February 7th, 2019, 01:23 PM   #19
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Quote:
Originally Posted by ducatiman View Post
Bolts, not nuts that hold the petcock to the tank, no?

10mm head, no? .....counter clockwise ONLY to loosen, get some PB blaster on it.

Any way you can invite an experienced mechanical type neighbor, relative or friend over for an assist?

Put out a call on the ninjette forum for a local, nearby member? We'd get it in 3 minutes (or less) if we were locals.
Right. It's a 10mm head. Haha that's not a bad idea.

I did the vacuum check with a turkey baster when I first cleaned the tank and got nothing. I'm not sure if that's even enough suction though. I'll give it another try!
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Old February 7th, 2019, 02:41 PM   #20
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Hey, Jack, figured I'll throw this out there for you.

If you decide to rebuild the petcock...prior to ordering anything... send it to me, I'll test it before to confirm, use my machines on it...then test it after....you providing or paying for parts only....IF NEEDED.

Its conceivable it won't even need anything other than intense cleaning and proper reassembly (all pending inspection and testing, of course). The machines really work wonders.

Up to you, I'm there if need be.
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Old February 7th, 2019, 03:05 PM   #21
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Here's similar thread: https://www.ninjette.org/forums/showthread.php?t=326499
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Old February 14th, 2019, 03:21 PM   #22
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Hey, guys! Thanks for all of the suggestions. It's been pretty cold here so I haven't been able to work on my bike for a while until today! (From 30 degrees last week to 60 Degrees today. lol Good ole Texas weather.)

I finally pried the petcock off and hoo boy. Haha I'll attach some pictures.

Compared to some of the pictures I've seen of what they should look like, I don't think cleaning it would even be in the question.

Both the inlets are completely eaten away and both the tubes they lead to are full of hardened gunk. The second pictures is from the bottom of the petcock looking down the tubes that should let the gas flow to the carbs.

Am I right in thinking I should just buy a new one? My finger is hovering over the "order" button for a cheap one (8 bucks) on ebay.
Attached Images
File Type: jpg Petcock Ninja.jpg (116.2 KB, 13 views)
File Type: jpg petcock ninja2.jpg (71.7 KB, 5 views)
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Old February 14th, 2019, 04:56 PM   #23
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New one would be best. But be aware that many of eBay ones won't fit. Notice there's certain length of tubing to place petcock well below mounting surface of tank (about 8cm). So far, none of vacuum petcocks i've seen on eBay will fit. The tubing section is too short and petcock hits overhanging side of tank.

There appears to be manual petcock that may work, but I haven't asked them for any measurements yet.
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Old February 14th, 2019, 05:27 PM   #24
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Originally Posted by DannoXYZ View Post
New one would be best. But be aware that many of eBay ones won't fit. Notice there's certain length of tubing to place petcock well below mounting surface of tank (about 8cm). So far, none of vacuum petcocks i've seen on eBay will fit. The tubing section is too short and petcock hits overhanging side of tank.

There appears to be manual petcock that may work, but I haven't asked them for any measurements yet.
Thanks. Yeah, I checked out a lot of the reviews for those cheaper ones and they seemed sketchy. I ended up spending the money to just buy an OEM petcock.
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Old February 14th, 2019, 06:17 PM   #25
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Jack-

send me the old one, let me see what I can do with it

PM me if you'd like to discuss further
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Old February 14th, 2019, 06:19 PM   #26
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Jack-

send me the old one, let me see what I can do with it

PM me if you'd like to discuss further
Sure thing! I'll send it to you as soon as I get the new one on the tank.
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Old February 14th, 2019, 06:30 PM   #27
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Originally Posted by JackTheAlbatross View Post
Thanks. Yeah, I checked out a lot of the reviews for those cheaper ones and they seemed sketchy. I ended up spending the money to just buy an OEM petcock.
I'm sure those petcocks will work just fine if they fit. But they're too short. Here's the critical measurement.





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Old February 14th, 2019, 06:56 PM   #28
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Sure thing! I'll send it to you as soon as I get the new one on the tank.
Understood.

Send all hardware too....note...aside from an obvious repair challenge, this effort is not for me, but for you.

Worst case scenario ...it goes in the can.

Best case scenario...you get yourself a working backup spare for next to nuffin'.
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Old February 15th, 2019, 07:36 AM   #29
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I'm sure those petcocks will work just fine if they fit. But they're too short. Here's the critical measurement.
We had one on a Ninja - and it was a real pain to turn on and off.
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Old February 21st, 2019, 11:41 AM   #30
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Got my new petcock installed on the tank and it works great! Thanks for the heads-up about the cheap eBay models. I decided not to risk it and bought the exact same part they have when they come out the factory.

Honestly guys, I'm stumped. I tried to get it to turn over and for a second it ran.

Conditions:
Choke fully engaged
petcock in On position(tried res as well)
relatively fresh gas from early January
Carbs blessed by Ducatiman
Freshly charged battery
Bit of starter fluid

Results:
5 seconds of uninterrupted idle with white smoke coming from tailpipes(mostly from the right tailpipe). Died when I disengaged the choke.

Could it be an electrical issue? Spark issue?

Gas is definitely getting to the carbs now. When I pull the petcock valve off, I get a bit of gas dripping and it stops which is what I've read is a good sign.

Last futzed with by JackTheAlbatross; February 21st, 2019 at 02:07 PM.
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Old February 21st, 2019, 01:21 PM   #31
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For the present time forget the smoke...

get it to start, full choke if necessary...then sequentially less choke, while using the throttle to keep RPM up... don't just immediately turn the choke off and expect it to idle...you haven't even done a final set on that yet!
The plugs may be on the verge of fouling (too much fuel)? Have you inspected or replaced the spark plugs?
Alternately, try a start attempt using FULL throttle/NO choke (it'll clear fuel from the chambers) ....be prepared to back off the throttle. (or the tach needle will fly off)

You didn't overcompensate, turning throttle adjuster up too much during prior start attempts, didja?

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Old February 22nd, 2019, 08:03 AM   #32
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PM sent this morning.
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Old February 23rd, 2019, 06:38 PM   #33
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Originally Posted by ducatiman View Post
For the present time forget the smoke...

get it to start, full choke if necessary...then sequentially less choke, while using the throttle to keep RPM up... don't just immediately turn the choke off and expect it to idle...you haven't even done a final set on that yet!
The plugs may be on the verge of fouling (too much fuel)? Have you inspected or replaced the spark plugs?
Alternately, try a start attempt using FULL throttle/NO choke (it'll clear fuel from the chambers) ....be prepared to back off the throttle. (or the tach needle will fly off)

You didn't overcompensate, turning throttle adjuster up too much during prior start attempts, didja?

"Dumcatiman"
"Dumcatiman"
Sorry, was in a rush to get to class. Haha I haven't touched the throttle adjuster since I got it.

Here's an update for you and everyone else:

I bought a multimeter to check for any electrical issues.

Results:
Battery - 12.89
Battery/Engine grounded - 12.89
Spark plugs - both had a spark when took them out and placed them on the head
ignition coil - 0.00...?


I actually think my engine may be flooded. When I took the spark plugs out and cranked the engine to see if there was a spark, a bit of fuel spat out of the cylinder (which scared the hell out of me considering the plug I was testing had a nice spark going). The plugs are brand new but the bottom ends were wet when I took them out.

Weird thing is that once I put everything back together, the bike idled perfectly with the choke on. Maybe I didn't have the new spark plugs seated correctly the first time. I released the choke bit by bit and it died out in the middle. Funny thing is that I can't throttle it at all without it dying now.

Despite all the trouble this bike is giving me, I'm still having a lot of fun trying to figure it all out. Thanks for all the help so far, everyone. I ain't giving up yet!
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Old February 23rd, 2019, 09:05 PM   #34
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MOTY - 2018, MOTM - Nov '17
Try letting it idle with choke ON for about 4-5 minutes.
Then set choke to 50% and test with a little throttle slowly and gently.
When it gets some revs up, you can take off.
Turn OFF choke 2-3 blocks away when you're moving at good speed.


Should also test petcock, I've seen many that's bad right out of box.

1. unplug fuel inlet line from carbs
2. unplug vacuum-hose going into petcock
3. plug 1-2 foot long vacuum hose into petcock's vacuum-inlet
4. aim fuel line from tank into measuring-cup
5. apply vacuum to petcock's vacuum-inlet
6. let fuel flow for 30-seconds

How much fuel did you collect?
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