Ignition System Struggles

Josh · 08-02-2020, 03:51 PM

Hello all,

So recently after I took my gz250 out on a bit of a hike, the starter motor stopped running. I ended up needing to push-start it a few times to get it home. I am currently attempting to troubleshoot the problem but I don't think I am making much progress

I am following the service manual and it says to check the voltage on the starter relay connector terminals when attempting to start. I read no voltage and see the list of components that may be at fault, but I'm not sure where to start or what the best way to go about further diagnostics would be. Any help with this would be hugely appreciated

alantf · 08-03-2020, 03:10 AM

Have you checked the fuses?

Josh · 08-03-2020, 10:45 AM

Yeah, all the fuses are good and the battery is holding around 12 [V] . I was reading around a bit and saw some people mention the starter button / emergency stop switch commonly get corroded so I took some dusting spray to the housing and managed to get it to crank once or twice.

So, I'm planning to take some CRC to it sometime this week and check up on the other kill switches in line and hopefully get it resolved, the small crank I did get sounded quite odd though, the relay definitely actuated but it quickly sputtered out.

alantf · 08-04-2020, 03:18 AM

Did you check if there's voltage to the inlet side of the relay?

Josh · 08-06-2020, 12:35 PM

By that do you mean the thick line from the battery or input to the primary coil? I did get a voltage reading directly on the thick line side, but not on the primary winding terminals when I attempt to start.

Will update after I clean up the starter button emergency switch connections, I'm pretty sure the other switches are in good condition but I haven't inspected them closely so I could be wrong.

alantf · 08-07-2020, 03:28 AM

There should be a constant voltage on the input side (thin wire) of the coil. Check between that terminal and ground. If you don't get a reading it's definitely a fuse. All the kill switches are on the output side of the relay coil, and go to ground.

Donald McPherson · 08-08-2020, 03:27 AM

Take the starter our and bench test it by bypassing the solenoid.
Switch, fuse, solenoid or starter. Most times it will be the solenoid.

Josh · 08-09-2020, 01:43 PM

Solenoid is definitely bad, ordered a new one for 5 bucks off ebay. I double checked all the fuses both visually and with a continuity check they are all good. In the meantime I guess I'll clean up the kill switches just to be sure there's good connection throughout the circuit.

Thanks for the help guys seriously, I need to get this thing running before I end up paying an arm and a leg in parking haha

Josh · 08-13-2020, 06:05 PM

The new relay did the trick! The bike is running great just as before with no problems starting thanks again for the help!

Donald McPherson · 08-14-2020, 07:09 AM

Good to hear. 9 times out of 10 it will be the solenoid before the starter gives up.

08-03-2020, 03:10 AM	#2
alantf Senior Member Join Date: Nov 2008 Location: Tenerife (Spain) Posts: 3,715	Have you checked the fuses? __________________ By birth an Englishman, by the grace of God a Yorkshireman.
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08-03-2020, 10:45 AM	#3
Josh Junior Member Join Date: Aug 2020 Posts: 5	Yeah, all the fuses are good and the battery is holding around 12 [V] . I was reading around a bit and saw some people mention the starter button / emergency stop switch commonly get corroded so I took some dusting spray to the housing and managed to get it to crank once or twice. So, I'm planning to take some CRC to it sometime this week and check up on the other kill switches in line and hopefully get it resolved, the small crank I did get sounded quite odd though, the relay definitely actuated but it quickly sputtered out. Login or Register to Remove Ads
	0

08-04-2020, 03:18 AM	#4
alantf Senior Member Join Date: Nov 2008 Location: Tenerife (Spain) Posts: 3,715	Did you check if there's voltage to the inlet side of the relay? __________________ By birth an Englishman, by the grace of God a Yorkshireman.
	0

08-06-2020, 12:35 PM	#5
Josh Junior Member Join Date: Aug 2020 Posts: 5	By that do you mean the thick line from the battery or input to the primary coil? I did get a voltage reading directly on the thick line side, but not on the primary winding terminals when I attempt to start. Will update after I clean up the starter button emergency switch connections, I'm pretty sure the other switches are in good condition but I haven't inspected them closely so I could be wrong. Login or Register to Remove Ads
	0

08-07-2020, 03:28 AM	#6
alantf Senior Member Join Date: Nov 2008 Location: Tenerife (Spain) Posts: 3,715	There should be a constant voltage on the input side (thin wire) of the coil. Check between that terminal and ground. If you don't get a reading it's definitely a fuse. All the kill switches are on the output side of the relay coil, and go to ground. __________________ By birth an Englishman, by the grace of God a Yorkshireman.
	0

08-08-2020, 03:27 AM	#7
Donald McPherson Member Join Date: Aug 2018 Location: Aberdeen Scotland Posts: 47	Take the starter our and bench test it by bypassing the solenoid. Switch, fuse, solenoid or starter. Most times it will be the solenoid.
	1

08-09-2020, 01:43 PM	#8
Josh Junior Member Join Date: Aug 2020 Posts: 5	Solenoid is definitely bad, ordered a new one for 5 bucks off ebay. I double checked all the fuses both visually and with a continuity check they are all good. In the meantime I guess I'll clean up the kill switches just to be sure there's good connection throughout the circuit. Thanks for the help guys seriously, I need to get this thing running before I end up paying an arm and a leg in parking haha
	0

08-13-2020, 06:05 PM	#9
Josh Junior Member Join Date: Aug 2020 Posts: 5	The new relay did the trick! The bike is running great just as before with no problems starting thanks again for the help!
	1

08-14-2020, 07:09 AM	#10
Donald McPherson Member Join Date: Aug 2018 Location: Aberdeen Scotland Posts: 47	Good to hear. 9 times out of 10 it will be the solenoid before the starter gives up.
	0