bike wont start,clicking, no headlight, battery is fine.

[zzrguy]

So long story short...
bike wont start,clicking, no headlight or highbeam, battery is fine.

Checked all fuses they are fine, battery was tested with flying colors, changed the starter solenoid, checked headlight connection was fine.
Now im confused. This just started randomly out of no where.... confused?

[flynjay]

Originally Posted by zzrguy

So long story short...
bike wont start,clicking, no headlight or highbeam, battery is fine.

Checked all fuses they are fine, battery was tested with flying colors, changed the starter solenoid, checked headlight connection was fine.
Now im confused. This just started randomly out of no where.... confused?

How do you know the battery is fine?

[zzrguy]

tested it at work :P I have a professional battery tester there

[lgk]

check the switch at the key or the starter relay

[zzrguy]

you guys gotta think of something crazy. I have a spare parts bike and i tried different ignition,kill switch,fuse-box,regulator/rectifier,main fuse/starter relay, checked all connections.....
only thing that's not normal is the headlight not coming on. could a burnt out light really cause a incomplete circuit preventing the bike from starting.

[alex.s]

Originally Posted by zzrguy

could a burnt out light really cause a incomplete circuit preventing the bike from starting.

no.

you probably have a short.

you say the "only thing thats not normal is the headlight not coming on"... as in, all the other lights work? brake light? neutral light? temp gauge/fuel gauge?

if nothing works you probably dont have a ground connection or something

is your battery connected correctly? its not backwards?

[zzrguy]

Originally Posted by alex.s

no.

you probably have a short.

you say the "only thing thats not normal is the headlight not coming on"... as in, all the other lights work? brake light? neutral light? temp gauge/fuel gauge?

if nothing works you probably dont have a ground connection or something

is your battery connected correctly? its not backwards?

no battery is connected fine lol and all the other lights work the just the headlight/ light that indicates headlight isnt working

[alex.s]

your forward controls probably arent connected properly? it would explain not starting and no headlight if the clutch sensor was out and no highbeam switch.

if you put it in neutral, the neutral light comes on. can you start it in neutral?

can you bump start it?

[zzrguy]

Originally Posted by alex.s

your forward controls probably arent connected properly? it would explain not starting and no headlight if the clutch sensor was out and no highbeam switch.

if you put it in neutral, the neutral light comes on. can you start it in neutral?

can you bump start it?

neurtal comes on and no it doesnt start, i havent tried bumping it and no they are connected fine

[alex.s]

you need to bust out your volt meter and start checking your wiring.

check the starter circuit first. it should work without anything else on the bike. try manually shorting the starter relay with it in neutral and see if it will turn... knowing if it will or not will cut your search tree down quite a bit.

[Panda]

I had something similar that turned out to be a short on the kick stand kill switch.

[zzrguy]

Originally Posted by alex.s

you need to bust out your volt meter and start checking your wiring.

check the starter circuit first. it should work without anything else on the bike. try manually shorting the starter relay with it in neutral and see if it will turn... knowing if it will or not will cut your search tree down quite a bit.

i can take the wire from the starter motor and hook it up to the positive of the battery and it should turn right?

[lgk]

i never did it that way but if it works like car, then it should work.

[alex.s]

just short the terminals on the starter relay, its easier and tells you more than taking the wire off and touching it to the battery.

[alex.s]

what i expect is that shorting it starts it fine in which case you should look at the starter circuit relay and headlight circuit relay. they are right above the battery if i remember right. maybe the battery got hot and blew both of them

[zzrguy]

Originally Posted by alex.s

what i expect is that shorting it starts it fine in which case you should look at the starter circuit relay and headlight circuit relay. they are right above the battery if i remember right. maybe the battery got hot and blew both of them

I tried and nothing. i tried jumping the bike didnt work. battery is fine i found out that if i have it in first and i have the clutch in i can start it and it will keep running.
when i start it in first it doesnt always start sometimes i have to wiggle it around for this to work.

neutral sensor switch?

[flynjay]

Originally Posted by zzrguy

I tried and nothing. i tried jumping the bike didnt work. battery is fine i found out that if i have it in first and i have the clutch in i can start it and it will keep running.
when i start it in first it doesnt always start sometimes i have to wiggle it around for this to work.

neutral sensor switch?

You either have a loose connection somewhere or one of your safety switches is intermitten.

Safety switches can be checked one-by-one by shorting them out. Except for the neutral switch which has to be working for the light to come on and is bypassed by the clutch switch.

Chasing down a loose connection can be a chore.

[zzrguy]

at first i figured it was a loose connection but now i narrowed it further down.
I tried all the saftey switches and the bypasses and nothing worked,so they must be fine. When ever i have it in first and the clutch in i have to roll in back until it stops moving... yes it stops moving with the clutch in and then i click ignite and it starts... ? um first of all shouldnt my bike roll with the clutch in, im guessing the starter motor is jamming or something like this?
but then again how can it be jamming if i can roll in neutral... good god sounds retarded. lol
I cant wait until my winter, i plan to rebuild the whole engine/ bike from scratch.

[alex.s]

can you roll forward in 1st with the clutch all the way in

[zzrguy]

Originally Posted by alex.s

can you roll forward in 1st with the clutch all the way in

no which is the weird part? i can only roll about half to a foot back and that's about it.
maybe me starter is pooped? or jammed because it does start and work.. weird

[alex.s]

are you sure its not just cold with a sticky clutch? put it in first and warm it up then turn it off and see if it will roll...

does it die if you start it in first then put it in neutral?

[Lychee]

It is possible the engine is being held in place by a stuck clutch. Firmly rock the bike in first with clutch in to break the plates loose and then try again.

You can also try banging on the starter with a wrench to see if that helps it move along.

Did the headlight come on when the bike did start?

[alex.s]

Originally Posted by Lychee

You can also try banging on the starter with a wrench to see if that helps it move along.

surprisingly, the "fonz" is a very useful trick for old bikes.

[Lychee]

Originally Posted by alex.s

surprisingly, the "fonz" is a very useful trick for old bikes.

I don't get the reference.

[zzrguy]

Originally Posted by alex.s

are you sure its not just cold with a sticky clutch? put it in first and warm it up then turn it off and see if it will roll...

does it die if you start it in first then put it in neutral?

clutch apparently not sticky. warmed it up and still did the same thing. as for putting it in neutral , it works fine and doesnt die... i tried hitting the thing with a wrench lmao didnt work :P figures...
I guess ill just ride it like this until i rebuild in winter time, i know how to start it even if it is retarded lol
and yeah both my lights work when its on.

[alex.s]

do me a favor and wiggle your front sprocket... see if it wiggles.

[zzrguy]

solid as a rock

[alex.s]

hm.

i blame ghosts.

[zzrguy]

Originally Posted by alex.s

hm.

i blame ghosts.

lmao i dont think there are many out in the country but okay lol :P

I'm just gonna rip the whole bike apart and hope for a late winter ill update you guys in two weeks or so once the full rebuild is done.

these kawis baffle me, thank god i work on hondas all day they are so much easier to understand lmao

[alex.s]

i was doing some reading and found a few people talking about how the ZZR250 has different electrical wiring setup than the normal EX250 but i havent been able to find the actual zzr wiring diagram or how its different. but im guessing here that theres something different on the ZZR that is causing this. cause looking at the EX wiring diagram, i dont understand how this is possible.

maybe the ZZR has some kind of tip-over sensor or something that is malfunctioning?

wait i found one:

[alex.s]

do you have a fuel pump and does it come on?

[zzrguy]

nope no pump just straight to the carbs from the tank.
mind me asking where u found the nice colorful diagram... My service manuals look like cheap crap compared to that lol

[alex.s]

google images. it was like 4 pages in when searching for ZZR 250 wiring diagram