Stupid electronics!

[MasterCylinder]

'90 ex250.

Turn signals don't work (didn't when I bought it) nor does my horn. I took a multimeter and it seems like all the connections are there. I hear the relay click once when I flip the turn signal switch but nothing happens. So I pulled the relay apart and it looks brand spanking new inside and I can't find any broken connections. Also the relay shows a full connection. Fuses are all good. In fact the fuse/junction box I have Doesn't have a turn signal fuse. Hell it only has 4 fuses versus what all the wiring schematics keep showing. =/

Maybe there is something I'm missing?

[CZroe]

Originally Posted by MasterCylinder

'90 ex250.

Turn signals don't work (didn't when I bought it) nor does my horn. I took a multimeter and it seems like all the connections are there. I hear the relay click once when I flip the turn signal switch but nothing happens. So I pulled the relay apart and it looks brand spanking new inside and I can't find any broken connections. Also the relay shows a full connection. Fuses are all good. In fact the fuse/junction box I have Doesn't have a turn signal fuse. Hell it only has 4 fuses versus what all the wiring schematics keep showing. =/

Maybe there is something I'm missing?

Stock turn signals? Relay will click once if one is blown but the other will come on and stay on.

[MasterCylinder]

Noted. Guess I'll Try and pick up a new one. =/


Question still remains though... My horn doesn't work either. =/

[DaBlue1]

You've checked the fuses, how about the bulbs themselves?
There are diodes for the turn signals near the rear of the bike. Check all the bulbs as well as simply replacing the relay. Make sure the battery is fully charged as well. As for the horn it is either the ignition switch or horn button itself. A horn upgrade wouldn't be bad either.

[MasterCylinder]

Originally Posted by DaBlue1

You've checked the fuses, how about the bulbs themselves?
There are diodes for the turn signals near the rear of the bike. Check all the bulbs as well as simply replacing the relay. Make sure the battery is fully charged as well. As for the horn it is either the ignition switch or horn button itself. A horn upgrade wouldn't be bad either.

Well It'd be kinda odd for all 4 bulbs to be out, but I'll look at them anyways.
Why would it be the ignition?

Wish there were pictures. I'm so lost =/

[DaBlue1]

Originally Posted by MasterCylinder

Well It'd be kinda odd for all 4 bulbs to be out, but I'll look at them anyways.
Why would it be the ignition?

Wish there were pictures. I'm so lost =/

Bulbs burn out. In 12 years anything is possible. The horn doesn't blow unless the ignition switch is working properly.

[n4mwd]

I think you mean 22 years - not 12 - if you were referring to the age of the bike that is.

You should have seven 10Amp fuses plus a 30A in a separate box. If you are missing them, that is probably your problem.

[DaBlue1]

Originally Posted by n4mwd

..I think you mean 22 years - not 12 - if you were referring to the age of the bike that is.

oops. yeah 22. damn fat fingers!

[Skippii]

You checked the fuses, four are missing, and you're still wondering why several electronics aren't functioning?
Posted via Mobile Device

[CZroe]

Originally Posted by Skippii

You checked the fuses, four are missing, and you're still wondering why several electronics aren't functioning?
Posted via Mobile Device

If he only knows that there are supposed to be more based on a wiring diagram that doesn't match what he sees, then he's probably saying that there are no empty sockets in his fuse box and that there are only four sockets total.

[Skippii]

You think someone put an aftermarket junction box on his bike? That could definately explain why some electronics don't work. Can you post a pic of your junction (fuse) box? I know some 80s boxes were different, but don't recall ever seeing one with no turn signal fuse.
Posted via Mobile Device

[MasterCylinder]

I'll take the actual pic of it after work today.... Here's one I found on google though...

[Skippii]

If you've got a different model junction box from an 86 or something, that could explain your problems. I've heard the plugs fit the same but the wiring is different. That's all from memory though, so I can't be sure of anything...
Posted via Mobile Device

[n4mwd]

It should look more like this:



The relay looking thing next to it is the flasher. There are 9 fuses, but the two on the bottom are spares and aren't hooked to anything.

Looks like the previous owner really screwed things up. You might be better off buying a whole new harness and fuse box off ebay.

Here is a new fuse box for $10 and free shipping.

They have wiring harnesses there too for about $15 delivered, but if you get one, its important to know that the wiring on the early pregens was different from later pregens. Look up the correct part number for your year on RonAyers and then make sure what you are buying matches.

[MasterCylinder]

Hmmm I thought it seemed kinda weird... Thought maybe mine was year specific or something. I'll pick up a new fusebox and see if that works. Looks pretty much plug'n'play. I'd rather not re-wire the bike though. I hate messing with wiring so much. =/


The flasher looks exactly the same as the one you showed but I went ahead and picked up another one just in case.

[n4mwd]

I see you bought that fusebox, I hope you have the original bracket to mate with it because the one in the listing didn't come with the bracket. Its not the end of the world if you don't, but it makes things a lot nicer if you do. Sorry I didn't think to mention that before.

The only reason I suggested getting the new harness is that it sounds like the previous owner cobbled your wiring. As such, the original fusebox connectors may be missing or wired incorrectly.

[n4mwd]

Oh, I just just noticed something. The ebay fuse box has incorrect fuse values in the slots. They should ALL be 10 amps. The only exception is the main fuse which is 30A, but it's external in the single slot fuse holder next to the starter relay.

I've attached a wiring diagram for the pregen Ninja 250 that might help you.

[MasterCylinder]

Originally Posted by n4mwd

I see you bought that fusebox, I hope you have the original bracket to mate with it because the one in the listing didn't come with the bracket. Its not the end of the world if you don't, but it makes things a lot nicer if you do. Sorry I didn't think to mention that before.

The only reason I suggested getting the new harness is that it sounds like the previous owner cobbled your wiring. As such, the original fusebox connectors may be missing or wired incorrectly.

Nothing on the bike wire wise has been touched/spliced so I'm not too worried about it right now...

Originally Posted by n4mwd

Oh, I just just noticed something. The ebay fuse box has incorrect fuse values in the slots. They should ALL be 10 amps. The only exception is the main fuse which is 30A, but it's external in the single slot fuse holder next to the starter relay.

I've attached a wiring diagram for the pregen Ninja 250 that might help you.

I noticed the the fuses too. I'll just swap them out. Not worried.

[MasterCylinder]

Got my parts today. Swapped the turn signal relay - they work now. Swapped the fuse box - nothing changed. I finally tracked down that it was the horn button itself though and apparently only needed a cleaning. So now my horn works....

But like how everything usually works something else does not work now... Headlight bulb went out and now I gotta figure out how to get that out without breaking something else and my fuel filter snapped in half when I was trying to disconnect the hose... It's like, seriously? There has to be a better way to connect it.

[n4mwd]

Fuel filter? You mean that plastic thing on the carb inlet?

[MasterCylinder]

Originally Posted by n4mwd

Fuel filter? You mean that plastic thing on the carb inlet?

Not mine.

[n4mwd]

The one in the photo is aftermarket. Are you saying that it broke in two? The OEM filter is just a little screen at the fuel inlet to the carb.

[MasterCylinder]

Originally Posted by n4mwd

The one in the photo is aftermarket. Are you saying that it broke in two? The OEM filter is just a little screen at the fuel inlet to the carb.

Yea I put an aftermarket one in (a much smaller one) and the ends snapped off almost like the plastic melted or something... So I gotta go get another one. =/

[DaBlue1]

Originally Posted by MasterCylinder

.... I put an aftermarket one in (a much smaller one) and the ends snapped off

Be careful putting on a smaller inline filter. Some can inhibit fuel flow. The Ninja actually has an inline filter on the carb as well.

[MasterCylinder]

Originally Posted by DaBlue1

Be careful putting on a smaller inline filter. Some can inhibit fuel flow. The Ninja actually has an inline filter on the carb as well.

When you say smaller inline ones, what do you mean?

Mine doesn't have that screen one. All the tubing had been replaced by the previous owner.

[DaBlue1]

Originally Posted by MasterCylinder

When you say smaller inline ones, what do you mean?

Some aftermarket inline filters may have smaller than average holes in the nipples on the filter, even though they may fit the fuel line hose.

[n4mwd]

Pregens built before 2000 didn't come with the inline filter. you need 1 that's made to work with gravity feed. I got mine at a lawn mower shop. The inlet and outlet are approximately 1 quarter inch.

[MasterCylinder]

I gotcha. I had this one and it seemed to work fine. Til it seems like the nipples melted. Cheap for sure.

http://www.cyclegear.com/eng/product...ter/web1007465


I'm gonna go back to the one the previous owner had that I thought was screwing up the bike. It's bigger (5/16") but we'll see. I'll find out tomorrow.



Also I can't seem to figure out the headlight thing. I ran a multi meter to everything connected to the headlight and there is a connection and power, the bulbs I used are brand new and it previously worked but it seemed hit or miss. Ideas on that?

[DaBlue1]

Originally Posted by MasterCylinder

I gotcha. I had this one and it seemed to work fine. Til it seems like the nipples melted. Cheap for sure.

http://www.cyclegear.com/eng/product...ter/web1007465

I had that one too. It had a flow problem and I took it off.

[MasterCylinder]

Good to know. Thank you for confirming that. Now I just need to find a way to orient the tubing so it doesn't screw with the flow.

[n4mwd]

The one I got at the hardware store works really good. It looks a lot like this one:



I can't swear they are the same, but the one I got was in True Value hardware in a plain plastic bag for about $6. The one on Amazon is a 60 micron, but I have never had a problem with flow.

[n4mwd]

Originally Posted by MasterCylinder

Good to know. Thank you for confirming that. Now I just need to find a way to orient the tubing so it doesn't screw with the flow.

Mine is oriented just like this one:


PS - I cut my original preformed stock tubing and left a gap for the filter. A friend used new tubing, but it kinked at the first 90 degree bend and restricted flow.

[MasterCylinder]

Originally Posted by n4mwd

Mine is oriented just like this one:


PS - I cut my original preformed stock tubing and left a gap for the filter. A friend used new tubing, but it kinked at the first 90 degree bend and restricted flow.

Well let me see how you have your's because that kink is what I was trying to avoid and the previous owner had but I can't think of a very good way to get it to work without kinking.

[n4mwd]

Originally Posted by MasterCylinder

Well let me see how you have your's because that kink is what I was trying to avoid and the previous owner had but I can't think of a very good way to get it to work without kinking.

Mine is identical to the one in the photo except I have a different filter. The OEM tubing is preformed and has the bend built in. All I did was remove about an inch in the middle of the horizontal part and put the filter in with new clamps. However, I suggest you use spring spring clamps and not the water clamps in the photo. The hardware store sells them.



You might get some polyurethane gas tubing that is more flexible. Might even be better, but you might have to step up to 5/16" tubing or something.

[MasterCylinder]

I ended up using 1/4" ID clear fuel hose, it's a really snug fit (had trouble pulling them off with 2 hands) so I'm gonna for-go the clamps for now. But it works and runs fine. It does have a minor kink but I figure the amount of vacuum in it will make up for it. If not then I'll be back to square one then.

On another note, still can't figure out the headlight problem. =/

[n4mwd]

Originally Posted by MasterCylinder

On another note, still can't figure out the headlight problem. =/

Just so we're clear, you do realize the headlights on a Ninja are smart headlights and don't come on unless the engine is running right?

Attached is a schematic that might help you figure out the problem.

[alex.s]

ah yes, the classic I.T. starter question... "Is it turned on?"

[MasterCylinder]

Yes I checked it today. It doesn't come on with the bike running. =/ It was working before. =/

[MasterCylinder]

Fixed the headlight issue... Apparently the pre-91 models had an older style 4 fuse system and the "newer" fuse box for some reason just doesn't work. Put the old one back on and everything works like a charm. Now to get it registered and actually ride it. >_< Thanks for the help guys.