Engine dies only when in gear

[bobganoosh]

Hi Guys - I've been lurking around this board for awhile now and can't tell you how much everyone's knowledge has really helped me out while in a few binds. This is by far the best resource I've found for information on the GZ250. Unfortunately I've finally hit a dead end with my current issue and could really use some advice on what may be causing the problem.

A little background... I live in Phoenix, AZ and own a '03 GZ with about 5-6k miles on it. It has always run beautifully until one scorching hot summer day about a month or so ago. I had just returned from a 30 or so mile ride at speeds of 65-70mph and was heading home on the side streets (45mph) when all of a sudden the bike started sputtering as though I had run out of gas. I quickly switched to the reserve tank, but to my surprise the bike simply shut down. Thankfully traffic wasn't too heavy at the time, so I navigated to a parking lot to try and figure out why the reserve didn't work.

Upon switching to neutral, I try to start her and she fired up right away... (i apparently still had a half tank left). Then the moment I switch into 1st gear, she shuts off as though the side-stand was down (of course, it isn't). And this is where I am completely lost as to what the problem might be.

I removed the tank to see if maybe the wiring had somehow melted and was shorting out, but everything appeared to look fine. My next thought is that maybe my turn signal / side-stand relay had blown, so I checked the turn signals and they work fine, but since I don't have a multimeter, I haven't been able to actually test it. If it's bad, will the turn signals still work?

And this is about as far as I've gotten so far. Am I even headed in the right direction? I'll do whatever I can to help you guys help me (pictures, more detail, etc), just let me know. And of course, any help on this will be GREATLY appreciated. Thanks!

:)

[jonathan180iq]

I might not be able to help you, but a video would probably be the best thing to show us.

Maybe just a 15 second video of the actual occurance.

[bobganoosh]

My camera doesn't do video, but I can borrow one. I'll see if I can get that posted up either a bit later today or early tomorrow.

Anyone have any other ideas in the meantime?

[Easy Rider]

Anyone have any other ideas in the meantime?

Let's not overlook the obvious. The side stand switch itself may be bad, have loose wires or be out of adjustment/bent. It should be fairly easy to by-pass it temporarily as a test.

[Jaime]

It must be something about that relay. The symptoms are clear.

[jonathan180iq]

I would have to agree, although I still would like to see what happens.

[bobganoosh]

Ok everyone... Thanks for responding with ideas this far. Here is a video of the problem:

http://video.tinypic.com/player.php?v=4t56h4z

Easy Rider: How would I go about with the by-pass test? Just remove the relay?

[caroledee1]

In the service manual, pages 6-15 and 6-16, will tell you how and where to test with a multi-meter. You can download the manual here in the troubleshooting

forum. :)

[bobganoosh]

Yeah, that manual is a god-sent. And this is pretty much where I came to a dead end. I'm not much of an electrician (I can swallow my pride and say that I actually don't know squat), so since I don't have a multi-meter, would something like this get the job done:

http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10051&langId=-1&catalogId=10053&productId=100013868

:??:

[caroledee1]

Yes, that should do the job.

[Easy Rider]

Easy Rider: How would I go about with the by-pass test? Just remove the relay?

Oops, I spoke too soon. Like the ignition switch, this is not a simple switch and it would appear that you can't simply short 2 wires together to disable it.

Let's forget about the relay for a while, OK, since it is not the most likely culprit.

More likely is a failure in the switch itself (located behind the kick stand) or the wiring leading away from it.

To keep running, that silver plunger must be pushed in by the arm attached to the kickstand.......and the contacts inside the switch must be making good contact. Is the spring on the stand broken, stretched or missing? Is the arm that is supposed to push in the plunger bent or broken? Is the switch itself bent, damaged or loose? Is the pivot on the stand too tight and binding?

It everything looks OK mechanically, that is the plunger goes in pretty much all the way and looks like it will stay there, then I'd try flushing the switch (plunger) with some alcohol and compressed air.

Unfortunately those switches are in a bad place; they collect a lot of water and dirt. Once they start going bad, it is usually best to get a new one.

It will be good to have a meter but you might not need it this time around.

Good luck!

[bobganoosh]

Easy Rider: You are the the man!!! :bow:

So I went out to have a look at the switch (sliver plunger) and noticed that one of the screws that holds it in place was missing. So when the side-stand is up, instead of pushing the plunger in, it was pushing it off to the side. I realigned the switch and replaced the missing screw... PRESTO!!!

I seriously owe you one as this has been driving me crazy! I would buy you a beer if Illinois was a little closer to Arizona :rawk:

And thank you to everyone else who put in their $.02 ... that's what makes this board the best place on earth for GZ help.

All in all, I feel a little sheepish for not figuring this out on my own, but I suppose I can't beat myself up too bad as this IS my first bike. What I am still curious about is why don't they have any diagrams or pictures of the silver plunger switch in the manual? Am I missing something?

[Easy Rider]

Easy Rider: You are the the man!!! :bow:

I seriously owe you one as this has been driving me crazy! I would buy you a beer if Illinois was a little closer to Arizona :rawk:


Aw, shucks.......it warent nothin, really!! :blush: :blush:

Put the Coors on my account. I'll collect later. :)

Experience is the best teacher........that is, sometimes the guys who know the most are the ones who have made the most mistakes !!! :tup:

[Water Warrior 2]

Bobganoosh, good catch with the switch and thanks to Easyrider's suggestion you are on the road again.