KLR650 No spark

Discussion in 'Thumpers' started by ozphotog, Oct 12, 2011.

  1. ozphotog

    ozphotog OZPHOTOG

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    Ok, now I am baffled, refitted the charged battery today...bike spins over, but no spark!

    Checked every plug connection I can find......all clean etc.

    How do I check if the CDI or the coil is stuffed?

    Ran fine yesterday, today no spark at all.

    If I unplug the switch from the clutch lever, I get nothing, no starter motor etc. Plug it back in and it spins over, so I presume the switch is ok.

    It has no side stand switch, can't see where it ever was or bypassed etc. (1992 KLR650 Tengai)

    Got me stumped.

    The charge rate to the battery seemed low when it did run, could it be a suspect stator? Does the CDI, coil etc, get their power from the stator or the battery?

    I checked the resistance on the 3 yellow wires got about 1.4 I think the manual says .8 - 1.0....is this a major concern?

    Help!!!!!
    #1
  2. ozphotog

    ozphotog OZPHOTOG

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    Just wondering what effect the lockout switches have, i.e. clutch switch, neutral switch....do they only affect the starter motor circuit or the ignition circuit as well?
    #2
  3. XDragRacer

    XDragRacer Long timer

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    If your bike has circuitry similar to the "Generation 1" ('87 to '07) KLR650's, the ignition circuit is completely separate from the battery circuit. Thus, assuming this situation, the battery's state of charge has nothing to do with the spark on your bike.

    The ignition's capacitive discharge ignition (CDI) system is powered by alternating current from the exciter coil of your alternator, only.

    Your critical components, IMHO, are--exciter coil of alternator (AC present when cranking?), pickup coil (triggers CDI to produce spark), CDI (a resistance chart matrix offers some help in checking out the device), ignition coil (rather straightforward, with resistance values typical of CDI system coils), and associated wiring (e.g., plug wire).

    If available, substitution of known operational components may help in your diagnosis; good luck!
    #3
  4. ozphotog

    ozphotog OZPHOTOG

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    Stripped it down today.
    Worked out the red wire from st stator plug supplies the power to the cdi.......spinning the engine over with a test light on it, gets nothing. Does this mean it is stuffed?

    If it ism waht do I need to order? I see stators for sale on ebay, but do they include the parts for the ignition?

    We figured by the fact that the starter spins over, none of the safety cut out switches are the problem. Have bypassed the side stand switch and the clutch switch.

    Looks like it must be a problem under the side cover.

    I notice some of the stators on ebay have one pole with no windings on it? Is this for the ignition system windings?
    #4
  5. ozphotog

    ozphotog OZPHOTOG

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    Talked to a brissy guy who rewinds stators.

    Said across red and white wire form stator whould be approx 180ohms......I get 140 or so.

    Across the trigger wires about 115ohms, and I get about that..

    This has me stumped.

    I don't want to buy new parts if the readings look ok.

    I do have to pull down the side to do the doo hickey, so maybe I should just do that and see if i can get someone to check out the stator and ign coil windings etc.
    #5
  6. ozphotog

    ozphotog OZPHOTOG

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    We did try swapping the CDI and the coil...no luck.

    The diode reads a little odd.....manual states should read 10 times resistance one way to other.
    Mine reads .6ohm one way ans 2.6 the other way....so it could be a problem.

    Problem is, kawasaki say only $59 but none in the country.

    I need a KLR650 GURU in brisbane that can sort this out for me!!!!!!!!!
    #6
  7. ozphotog

    ozphotog OZPHOTOG

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    Rang Kawasaki Service, He gave me a ph no of a company who spin up the stator and flywheel to check it.

    Seeing I have to do the Doo...I am gonna strip it down and get the stator etc checked, if nothing else, it will verify if it is ok or not....one less thing to worry about on a ride.

    Company is Cycletronics at Jimboomba if anyone is interested.....ph 32000720
    #7
  8. Trailryder42

    Trailryder42 Long timer

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    Do you have a red ignition switch on the right handlebar? Is it set to run?
    #8
  9. ozphotog

    ozphotog OZPHOTOG

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    Yes, That is a pretty obvious one.

    I have checked the circuitry on that. It is fine, as is the ignition switch.
    The ohn readouts on the Excitier coil and the ignition pickup coil are both well within the stats.

    Seems to me like it would be a bad connection or a short somewhere, but I have been all over the bike.

    This is really frustrating.

    Just rang Cycletronics about checking the stator, exciter coils etc. They only charge $10!!! She said the ohm readings in the manual are not right for Australian standards.....interesting....guess I will pull it down on the weekend and drop it off to them next week.
    At least that will take one part out of the list to check.

    Glad it is not my daily transport!
    #9
  10. Beezer

    Beezer Long timer

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    the diode readings in the manual were made in the days of analog meters.... digitals come up with different numbers. you need to know what a "diode number" is for your meter.... typically 400-600 ohms in forward bias, infinite in reverse... and some of the charts in the manual have the readings reversed as well

    something that can cause this problem is loss of the key in the rotor/shaft, it usually happens just AFTER doing the doo. the key gets knocked out during install, bike runs for while, then the rotor slips & everthing is out of time
    #10
  11. RevBill

    RevBill Irreverent Reverend

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    .. these may be obvious .. and I may have missed where you checked these already .. but ..

    .. plug wire replaced/swapped?
    .. good plug?
    #11
  12. 8gv

    8gv Long timer

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    Kind of exotic, but I like this one.

    Only thing is, would this result in no spark or only a spark at the wrong time?
    #12
  13. subybaja

    subybaja Long timer

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    Not so exotic, but...are you sure about the sidestand switch? Did the Tengai not have one, or is it just jammed up out of sight?

    THIS wiring diagram doesn't mention the Aus version not having one...
    #13
  14. ozphotog

    ozphotog OZPHOTOG

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    Found the side stand wires taped together when we pulled the loom apart. Have to solder them and a few other, so don't believe they are the issue.

    Kind of discouraging how many posts on here and klr650.net about klrs with no spark, and always problem to trace.
    #14
  15. ozphotog

    ozphotog OZPHOTOG

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    OK, pulling the side cover off tomorrow, getting the pick up coils, exciter coils etc checked by Cycletronics next week.
    Ordered another wiring loom from ebay seller last night....should fix all crappy wiring problems.

    Hopefully will find the problem soon...I just want to get out and ride!
    #15
  16. ozphotog

    ozphotog OZPHOTOG

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    Pulled the stator today.

    The pickup coil wires are as hard as rocks, from age and heat, one broke off in my hand. Looks like they had been resoldered or reconnected where they go through the grommet. I may run new wire and replace all the old hard stuff.

    Can't get the rotor off atm, the threads look bad in it and I can't get the puller to thread in.

    Is there a difference in the thread on the pre 2007 and post 2008 models?
    #16
  17. ozphotog

    ozphotog OZPHOTOG

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    Frustrating to find all these problems, but as it was never supposed to be complete tear down restoration, at least I am finding things that could be a problem later.

    Once I get the new loom, I will be happy to get rid of the PO shonky wiring.
    #17
  18. hoyks

    hoyks Tightass KLR rider

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    As far as I know, the safety locks will stop the started working as well as cut the spark. It might be as simple as a bad earth somewhere.
    #18
  19. ozphotog

    ozphotog OZPHOTOG

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    Pulled the flywheel today, removed the Doo, found it had a crack in it.
    Retired the pulse sender, got rid if the old broken wires.

    Gradually finding all the problems. Maybe I should have planned for a complete pull down in the first place.
    #19
  20. ozphotog

    ozphotog OZPHOTOG

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    Replaced the Doo.....sent the stator etc off to be tested....hopefully hear today.

    Ordered a replacement wiring loom from ebay.....will get rid of all the butchered wiring by the previous owner.

    Hopefully then I can get her going!!!!!

    I can't see what else could be stopping it sparking.
    #20