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Old 10-14-2011, 10:14 PM   #16
ozphotog OP
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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?
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Old 10-14-2011, 11:41 PM   #17
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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.
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Old 10-15-2011, 01:34 AM   #18
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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.

hoyks screwed with this post 10-15-2011 at 11:40 PM
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Old 10-16-2011, 12:34 AM   #19
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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.
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Old 10-17-2011, 09:11 PM   #20
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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.
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Old 10-23-2011, 07:56 PM   #21
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Got the stator back on the weekend, he said it all checked out ok.....but still no go.

Still waiting for the wring loom.....maybe that will fix things.......sooooo frustrating!
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Old 10-23-2011, 11:38 PM   #22
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Just checked the ignition exciter coils at the plug, ohm reading is fine....and get about 50v out of it when I spin it over.

Checked the red wire INPUT into the CDI and get the same 50v......so the powere seems to be getting TO the CDI.....what to I check to see if it it getting OUT to the coil?? Or which wire do I check to see if a switch or wire is earthing out somewhere??
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Old 10-24-2011, 01:41 AM   #23
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Well, sems the wires in and out of the CDI are all doing the right thnk, either earthing or not earthing depending on the kills switch or ignition switch.

The only thing I can think now is either the CDi or the Coil or the diode are cactus.

Anyone in Brisbane with some spares, or a running bike thry wouldn't mind swapping some but over to diagnose the problem?

Give me a call on 0416 275 730....or PM me.
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Old 10-26-2011, 02:12 AM   #24
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I could take a bunch of pictures of what my wiring looks like in pertinent areas. The pictures may be super helpful.
I've got a crappy lookin bike that runs very well and you have a very nice lookin bike that runs poorly! Ahahaha.

I would be glad to take dozens for you in locations that you need.
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Old 10-26-2011, 02:30 AM   #25
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thanks for the offer, but I think the wiring is not the problem, even tho the PO stuffed about with it.

The CDI is getting power when I spin it over.....the other wires appear to be doing what they are supposed to do....
I am pretty sure it is the CDI

I have bought another wiring loom off ebay, hopefully here any day now, will swap that first and see if I have any joy, then maybe take it off to the dealer!!
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Old 04-01-2013, 07:03 AM   #26
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So what wasa the final fix?

So my KLR is doing the same thing, everything works, just no spark. But all I have to do is turn the key off and on, then she starts right up.

So what was the final fix for your KLR?
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Old 04-01-2013, 10:18 AM   #27
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Sometimes the wiring can be loose around the starter solenoid.
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Old 04-01-2013, 12:03 PM   #28
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Old 04-01-2013, 02:10 PM   #29
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I ended up replacing just about everything electrical on the bike but I think the real problem was the cdi.
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Old 04-01-2013, 05:43 PM   #30
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MY KLR did a similer thing.I traced it to the plug coming from the key switch (I think red or red and white wire). I re-cripped the spade plugs and it's been fine ever since. When mine did this the bike would run and push start however the head light would not work.
Also had this type of issue riding and it was inside the key switch. The contact plate was falling out the back of the switch. as the were the bolts. lock tight and new bolts fixed it.
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