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SIKPUPY
11-15-2008, 10:25 PM
Hi

I found this forum and thought that someone may be able to help.

I have had a GZ and a GN for a couple of years now without any problems.

While I had a student on my GZ the other day it died and this is what we found

Headlight blown.. ( I think this happened the other day)
Battery was steaming, we removed the battery ASAP when I got it home.

I have now put a new battery in it, checked everything over and found that the no start switch on the stand was faulty so I bypassed it, checked all other wiring that I know of and I have power everywhere but have no spark. I swapped coil packs over from the GN as they are the same and there is nothing wrong with it.

Anyone got any ideas ?

eyeore302000
11-15-2008, 10:34 PM
Make sure you check all your fuses. I had one that blew and dorve me nuts for a couple hours till I figured it out.

Sarris
11-16-2008, 09:36 AM
Replace the stand switch. I'm pretty sure bypass won't work.

Please do a seach on site for "side stand switch" and you'll find a herd of info regarding what a little bastard that switch and circuit can be.

Also, a "steaming" battery may mean that you have a charging system problem. Usually it's an overcharge causes a battery to boil and possibly appear to steam.

You might also try changing the ignitor and the rectifier if they are the same.

Good Luck.

:)

Easy Rider
11-16-2008, 11:27 AM
I have now put a new battery in it, checked everything over ......................... I have power everywhere but have no spark.

Have you checked the charging voltage to be sure you don't "boil" the new battery ??

K.I.S.S. :) While everybody has a tendency to lump all the symptoms together and look for a single cause, that might not be the case at all. You can minimize that confustion by fixing the "little things" as they occur instead of letting them build up.

SO.....if you haven't already, change the spark plug. They occasionally short internally and when laid against the head, it appears there is no spark.....but the spark is there, it's just going from shell to head instead of across the gap. With a thumper, the spark plug is VERY important! :biggrin:

OTOH, if the rectifiers or regulator failed and you were pumping out AC or a high voltage DC, then a LOT of things could be fried.

Good luck. This doesn't sound good. :cry:

SIKPUPY
11-16-2008, 09:21 PM
I have changed the plug and checked all the fuses. I have not checked the charging voltage as I am unable to get it started. Once I get it started I am going to check everything as I dont want to destroy another battery.

Does someone have a wiring digram of the charging system and or electrical system so that I can go through it ?

Easy Rider
11-16-2008, 09:38 PM
Does someone have a wiring digram of the charging system and or electrical system so that I can go through it ?

Complete service manual available here for downloading.
Look into the "How To's" forum.
Lots of "black boxes" in the ignition though.

SIKPUPY
11-16-2008, 09:58 PM
Does someone have a wiring digram of the charging system and or electrical system so that I can go through it ?

Complete service manual available here for downloading.
Look into the "How To's" forum.
Lots of "black boxes" in the ignition though.

Yeah, just found it, looks to be a bit beyond my level of expertise.

5th_bike
11-16-2008, 10:31 PM
Hi
[...] the no start switch on the stand was faulty so I bypassed it
Hi.
Chances are the side stand switch is good - it has a diode in it, so a regular continuity check will indicate that it is no good, when it actually is good.

Remove the bypass and if you have voltage in your ignition circuit with the side stand up and the bike in gear, it's good.

Did you also try switching out ignitors?

SIKPUPY
11-16-2008, 11:19 PM
I believe that the ignitors are different between bikes. I have given up as I cant afford to have a bike down while I try and work it out as time is money. It is on the trailer and off to the shop.

Thanks for all your help

Badbob
11-17-2008, 06:52 AM
I believe that the ignitors are different between bikes. I have given up as I cant afford to have a bike down while I try and work it out as time is money. It is on the trailer and off to the shop.

This is probably a smart move. If you don't have the parts to swap from a working GZ250, proper test equipment, and a working knowledge of electricity troubleshooting this kind of problem can be difficult, time consuming and expensive. I have the equipment, knowledge, and another GZ250 and still it took me almost two months (longer if you count the months that it was intermittent) to track down a no spark problem that was caused by a pin hole in a wire in the headlight.

As far as I can tell the ignition parts are the same unless you have a Kalifornia version.

DaddyMav
03-02-2009, 11:42 PM
Well, I'm at the same place as SikPuppy. Did this problem ever get solved? I've tested the wires going to the coil and one gives me constant current when the switch is on. The other wire gives me voltage when I turn the bike over via the starter switch. Does anyone know what kind of numbers I should be getting here? The coil looks good per the specs in the manual. I got a new one and tried that but I'm in the same spot. Any ideas I can try from here?

SIKPUPY
03-03-2009, 04:37 PM
Mate

It did get solved and it wasnt cheap. Unfortunately it was really bad news :o(

Here is what happened

The Voltage regulator died, it then overcharged the battery, blew a few globes and then took out the CDI. I had the CDI sent away for repairs but it was too far gone to bother fixing. So after a new battery, CDI, regulator, a few globes and sockets it was good to go.

All up it ended up costing me about $800.00 AU

I hope this helps.

alantf
03-04-2009, 06:15 AM
Please excuse my ignorance, but what's a CDI?

Oh, by the way, SIK. Just got an e-mail from my mate in Baldivis. He's just sold up & bought a place in Secret Harbour. he's sent me the photos - Blimey, you could get my place in the Kitchen!

patrick_777
03-04-2009, 06:56 AM
Please excuse my ignorance, but what's a CDI?

Capacitive Discharge Ignition. The electrically-controlled ignition system on a lot of modern engines.

The GZ250 uses a Transistor-based Ignition System. A diagram of which is on page 6-18 of the downloadable Service Manual.

It's possible the Euro/Aussie specs for the GZ actually DO use a CDI. Though, it would be wise to check the manual first.

DaddyMav
03-04-2009, 11:30 PM
Well, we will see what the problem is in a few days. I brought it up to the local mechanic. I'm keeping my fingers crossed now.

DaddyMav
03-09-2009, 12:15 AM
Well I just got the bike back from the mechanic and it turned out being that the PO had messed with the pulsar coil and put it in backwards. It was getting spark but not at the right time. Now the bike is running like a champ and it is on to bigger and better things, like getting the body parts fixed up and painted.

mr. softie
03-09-2009, 02:40 AM
That is great news! Glad it works and thanks for posting. Who woulda thunk?

patrick_777
03-09-2009, 10:02 AM
These bikes are so prone to tinkering that you really never know what, or how far, a PO had their hands in.