ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 10-12-2011, 01:50 AM   #1
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
Question KLR650 No spark

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!!!!!
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-12-2011, 01:53 AM   #2
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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?
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-12-2011, 06:06 AM   #3
XDragRacer
Beastly Adventurer
 
Joined: Mar 2009
Oddometer: 2,740
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!
XDragRacer is offline   Reply With Quote
Old 10-12-2011, 07:29 PM   #4
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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?
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-12-2011, 07:49 PM   #5
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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.
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-12-2011, 07:53 PM   #6
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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!!!!!!!!!
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-12-2011, 09:26 PM   #7
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-13-2011, 07:39 AM   #8
Trailryder42
Beastly Adventurer
 
Trailryder42's Avatar
 
Joined: Oct 2006
Location: Amarillo, Texas
Oddometer: 1,054
Do you have a red ignition switch on the right handlebar? Is it set to run?
__________________
'00 XR440
'04 KLR650
'09 Wee Strom
COHVCO
USA-ALL
BRC
Trailryder42 is offline   Reply With Quote
Old 10-13-2011, 02:29 PM   #9
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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!
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com

ozphotog screwed with this post 10-13-2011 at 02:56 PM
ozphotog is offline   Reply With Quote
Old 10-13-2011, 03:05 PM   #10
Beezer
Beastly Adventurer
 
Joined: Oct 2004
Location: Anchorage, formerly Spenard (hub of the universe)
Oddometer: 5,250
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
Beezer is offline   Reply With Quote
Old 10-13-2011, 04:10 PM   #11
RevBill
Irreverent Reverend
 
RevBill's Avatar
 
Joined: May 2008
Location: Mayodan, NC
Oddometer: 2,104
.. these may be obvious .. and I may have missed where you checked these already .. but ..

.. plug wire replaced/swapped?
.. good plug?
__________________
"On the road less traveled there ain't no TP, bring your own and that will make all the difference.."
RevBill's SmugMug Shenanigans
My '06 KLR
RevBill is offline   Reply With Quote
Old 10-13-2011, 04:45 PM   #12
8gv
Beastly Adventurer
 
Joined: Nov 2009
Location: North central CT
Oddometer: 2,245
Quote:
Originally Posted by Beezer View Post
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

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?
8gv is offline   Reply With Quote
Old 10-13-2011, 06:36 PM   #13
subybaja
Beastly Adventurer
 
subybaja's Avatar
 
Joined: Jul 2007
Location: Anchorage (Spenard)
Oddometer: 2,888
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?

Quote:
Side Stand Switch This safety lockout prevents the rider from riding off with the kickstand down. It affects only the ignition system and prevents the ignition system from operating when the switch is engaged. The switch controls the ignition system by making or breaking the connection to ground. The Green/White wire comes from the diode bank and grounds via the Black/Yellow ground wire when the side stand is up.
THIS wiring diagram doesn't mention the Aus version not having one...
__________________
We had part of a Slinky. But I straightened it.
subybaja is offline   Reply With Quote
Old 10-13-2011, 09:44 PM   #14
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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.
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Old 10-14-2011, 03:34 PM   #15
ozphotog OP
OZPHOTOG
 
ozphotog's Avatar
 
Joined: Nov 2010
Location: Brisbane QLD Australia
Oddometer: 226
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!
__________________
Ozphotog
1992 Kawasaki KLR650 Tengai
Brisbane QLD AUS
www.scdetailing.com
ozphotog is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 08:38 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014