2002 gz250 wiring problems

H

Horny Porcupine :)¤FC¤

New member
:fight2:Hey everyone,
I am having problems getting this bike to fire. The wiring harness was just about butchered from the last owner who had it. No switch, he just hot wired it and tried to by-pass all the other switche on the kickstand, nuetral, and about everything else he could. Now the bike is on the lift in the shop and we have replaced the ignition switch and tried to repair everything else. I still can't get fire to the plug. Does someone have a solution or a wiring diagram so I can check myself before it costs me any more damage to the bike or my slim wallet?
Thanks,
Dennis
 
First, are you SURE that you have a valid title?
Sounds fishy to me. :shock:

A shop manual can be had from any Suzuki dealer for about $30.
With the extent of the "modifications", I doubt that anybody is going to be able to walk you through it by remote control.

Just remembered that there is a security feature built into the ignition system and only an OEM Suzuki ignition switch will work.......unless you know the secret, which I don't.

Good luck!
 
you probably have a bunch of switches to check - clutch, neutral, kill, ignition, and possibly kickstand.

now, do you actually get the motor to turn over at all? or does it turn but not ignite?
 
I appreciate the info you guys have given. As far as I know, the switch was replaced with an OEM one. Here at the shop the bike turns over but no spark, and oh yeah, the bike ain't stolen, easyrider. I called the local suzuki shop in Rome, Ga. and they told me a week out and around 60.00 dollars for the repair manual. I didn't know about the security feature on the switch and when I get back to the shop tommorow I will ask Jim about it. We both think that maybe the box might be bad and that might be where the problem is. Again I want to thank you guys and I will let you know what we find out.

Dennis
 
check if you actually get spark. pull the plug out but keep the wire connected, and then clamp / connect the threaded portion of the plug to somewhere on the engine, so that the tip is visible. now, crank it and see if you get spark across the tip of the plug. that will at least tell you if you get spark, though it won't tell you if the timing is right.

if you don't get spark, then work your way back through the connections until you get signal of some kind.
 
I saw that mentioned in one of the GZ forums I visit.
The guy that had the problem said he was SURE his ignition box was bad........until he found out it was the switch.
Good luck!
 
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