Hi there, I have exactly the same engine as you, but with a bigger size carb I think. My chassis is completely rusted over, but my main concern at the moment is to get the engine started. Cleaned out the carb last night, everything seems fine. But I can't make sense of the wiring loom AT all. The control box has completely deteriorated so the starter button will not work. Had to short out the starter solenoid in order for it to crank. Can you or anyone else give me a diagram for this engine?
Hi there, My engine does not have any problems that I know of and seems to be perfect with no wear. Yea the lack of rust proofing probably caused the rust of the frame, mine was not bad to be honest, but as i said, I went ahead and stripped it down to steel and layed down 2 coasts of acid etch primer then 3 coats of grey primer, and im on the main coat now.
Yea the wiring looms are a mess, connectors are hopeless also, if you engine is the same as mine, you should have two connectors coming out of the engine a big one and a small one, the small one is just a gear select switch telling when the engine is in neutral. On the big connector from the engine the blue/white and the green are the main wires needed for starting as the others are for the charging of the battery and such.
That is the basic idea and the rest can be followed from the diagram, as its hard to know without getting to the magneto which wires are for charging and spark.
Here is the closest I found:
http://media.photobucket.com/image/zongshen%20250cc%20wiring/starmotor/Z250wiringdiagram.jpg
Bare in mind that this is for a bike so has all the wiring for lights and horn and all other road legal bikes essencials, just print it off and scribble out what is not needed.
But here is one I prefer, alot simpler and easier to follow but some of the wire colours are different.
http://www.pitpro.com.au/support/Wiring%20Diagrams/250cc%20wiring.jpg
