ZXR250 CDI PROBLEM

Hi, You're on the right track, just check those out. Check the distributor cap it could have a crack in it too. If you're not getting any spark than it would be the ignition module. Have you had any codes from the computer this will narrow it down to 1 or 2 items. Good luck.

I have the same problem mate, I have been told to check ignition switch / barrel

hi
The firing pattern for a ZXR250 1996 is :-

#1 - #2 - #4 - #3

Good Luck

Ride Safe
Bike-Doc

what comes out of CDI box? if you have it going in it is rectified and more will come out. If not change CDI

rear brake pedal?

you run the positive lead from the cdi to the positive lead on the coil.... then somewhere between the negative lead on the coil and the frame/engine ground you splice in the kill switch.........what that does is breaks the ground when you push the kill switch which then kills the spark to the motor

Hi and welcome to FixYa,

Just to verify and eliminate the ignition coils, tests for it are:

• one terminal would have an IGN +12;
• the other terminal would have a pulsating voltage when cranking;
• passive test, primary (+ to -), resistance 3 ~ 5 ohms; while
• any of the primary terminal to HT would be 15 ~ 18 kilo ohms.

The CDI could not be tested since it is a sealed unit. The only way to confirm if it is a CDI is to check the external factors and if they are present yet no spark, then it would be the CDI:

• the CDI gets its triggers from the pulser coils;
• the output of the pulser coils would be very very low ACV;
• it would be preferable to use an analog/needle type multitester for the flickering pulser voltage;
• the CDI also needs a "go signal" from the interlocks together with the starter relay;
• try exercising the sidestand when cranking;
• verify neutral light is on;
• try starting with the clutch lever pulled.

Another possibility to consider is that the starter is consuming most of the power from the battery leaving very little for the ignition system to use and/or the ignition switch has some loose connection. The IGN +12 to the coil terminal should also test this possibility.

Please postback results / updates of tests performed.

Good luck and thank you for using FixYa.

Hi .... You might have to go through Kawasaki or a good dealer may have some in his workshop. Do not sand or grind the ones you have as you will remove or reduce surface hardness. A good engineering firm (with an accurate lathe) could make you a few in Stubbs steel if you provide a pattern and state the sizes you require.
Tell me where you are based and I might be able to make suggestions.

Hi,

To my knowledge, a 1987 Kawasaki EX500 uses a TCBI with digital advance to fire the ignition coils upon receipt of pulse from the trigger/pickup coils.

Since the pickup coils are new, and you have swapped the ignition coild, replace the high tension wires and checked/replace the spark plugs, the the only cmponent left is the CDI (electronic ignition system).

Hope this be of initial help/idea. Pls post back how things turned up or should you need additional information.

Good luck and kind regards.

Thank you for using FixYa.