30A main fuse blows

j.cuesta · October 28th, 2011, 10:05 PM

hey guys,

having a common ninja problem and need helping diagonising.

so the 30a main fuse keeps blowing. i check all the wiring and it kept blowing during riding around the block.

so rechecked everything and now when i put a 30a in and close the cap for the solonoid it blows even when the ignition is in the off position.

any ideas? i'm guessing the ignition switch, do you guys have any ideas.

thanks
tom

j.cuesta · October 28th, 2011, 11:50 PM

so i figured it out. been up all night figuring it out. turns out the ignition switch was f***** so had to jerry rig up all the ignition wires at the plastic connector above the engine.

Alex · October 29th, 2011, 07:58 AM

/thread moved to pre-gen tech area

j.cuesta · October 29th, 2011, 09:27 AM

hey guys,

so after wiring it all up bypassing the ignition switch still having a problem getting it started. i have the white connected to brown which is the only circuit that should matter and the engine cranks over fine but will not start. tried the screwdriver in sparkplug and i think i'm not getting spark. any ideas? bike was running but ignition switch became faulty and kept shorting the 30a fuse.

thanks guys

j.cuesta · October 29th, 2011, 09:46 AM

was reading online. when i bypassed the ignition i did brown to white but i read that grey needed a resistor or something of that kind. any truth to that or does grey just hang?

j.cuesta · October 29th, 2011, 10:06 AM

here's what i found...

I guessed that you might have messed with the ignition, for the purposes described by your nick.

I'll wager a guess that your CDI is from a 1994 bike or newer. If that's the case, it sounds like you haven't activated the (what seems to be the) primitive anti-theft system.

There is a grey wire on the ignition switch wiring harness; I'm not sure if it's grey on the CDI as well. It needs to be connected through a resistor to battery either at the exact same time as the CDI receives power (brown wire? If not white.. memory fuzzy), or slightly before. If you make the connection AFTER the CDI receive power, or forget the connection entirely, the CDI will NOT fire the plugs.

I'm 95% sure it's a 10 ohm resistor. If it's not 10 ohms, it's 100 ohms. I would buy both and try 100 ohms first if I were you.

It's also not in the schematics in the service manual, the manual shows grey not being connected all. I had to take apart the ignition switch to figure this out. There is a resistor connected from the brown wire (I think) to the grey wire contact, soldered right on the switch terminals under the plastic cap.

Wes

so i need a 100 ohm resistor on the grey wire. the problem is how do i wire it? grey wire, battery, positive terminal on batter or something?

thanks

October 28th, 2011, 10:05 PM	#1
j.cuesta ninjette.org member Name: julian Location: nyc Join Date: Oct 2011 Motorcycle(s): 02 ninja 250 Posts: 12	30A main fuse blows hey guys, having a common ninja problem and need helping diagonising. so the 30a main fuse keeps blowing. i check all the wiring and it kept blowing during riding around the block. so rechecked everything and now when i put a 30a in and close the cap for the solonoid it blows even when the ignition is in the off position. any ideas? i'm guessing the ignition switch, do you guys have any ideas. thanks tom

October 29th, 2011, 07:58 AM	#3
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	/thread moved to pre-gen tech area __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

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October 28th, 2011, 11:50 PM	#2
j.cuesta ninjette.org member Name: julian Location: nyc Join Date: Oct 2011 Motorcycle(s): 02 ninja 250 Posts: 12	so i figured it out. been up all night figuring it out. turns out the ignition switch was f***** so had to jerry rig up all the ignition wires at the plastic connector above the engine.

October 29th, 2011, 09:27 AM	#4
j.cuesta ninjette.org member Name: julian Location: nyc Join Date: Oct 2011 Motorcycle(s): 02 ninja 250 Posts: 12	hey guys, so after wiring it all up bypassing the ignition switch still having a problem getting it started. i have the white connected to brown which is the only circuit that should matter and the engine cranks over fine but will not start. tried the screwdriver in sparkplug and i think i'm not getting spark. any ideas? bike was running but ignition switch became faulty and kept shorting the 30a fuse. thanks guys

October 29th, 2011, 09:46 AM	#5
j.cuesta ninjette.org member Name: julian Location: nyc Join Date: Oct 2011 Motorcycle(s): 02 ninja 250 Posts: 12	was reading online. when i bypassed the ignition i did brown to white but i read that grey needed a resistor or something of that kind. any truth to that or does grey just hang?

October 29th, 2011, 10:06 AM	#6
j.cuesta ninjette.org member Name: julian Location: nyc Join Date: Oct 2011 Motorcycle(s): 02 ninja 250 Posts: 12	here's what i found... I guessed that you might have messed with the ignition, for the purposes described by your nick. I'll wager a guess that your CDI is from a 1994 bike or newer. If that's the case, it sounds like you haven't activated the (what seems to be the) primitive anti-theft system. There is a grey wire on the ignition switch wiring harness; I'm not sure if it's grey on the CDI as well. It needs to be connected through a resistor to battery either at the exact same time as the CDI receives power (brown wire? If not white.. memory fuzzy), or slightly before. If you make the connection AFTER the CDI receive power, or forget the connection entirely, the CDI will NOT fire the plugs. I'm 95% sure it's a 10 ohm resistor. If it's not 10 ohms, it's 100 ohms. I would buy both and try 100 ohms first if I were you. It's also not in the schematics in the service manual, the manual shows grey not being connected all. I had to take apart the ignition switch to figure this out. There is a resistor connected from the brown wire (I think) to the grey wire contact, soldered right on the switch terminals under the plastic cap. Wes so i need a 100 ohm resistor on the grey wire. the problem is how do i wire it? grey wire, battery, positive terminal on batter or something? thanks