disaster wiring - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 17 Old 10-24-2013, 05:31 PM Thread Starter
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disaster wiring

hello....im new to this forum or any other forum so please forgive me for my inexperience.i have bein replaceing a klr 650 motor on my beat up project dirt buggy that i bought to restore......problems all the way....but now at final stages wiring this beast an getting her fired up.when i bought my replacement engine i replaced the starter clutch with my old one as bike breaker assured me that was all which was wrong wit my replacement motor.first thing i noticed was new engine had a cluster of 5 wires from engine.my old one had the same 5 wire cluster but another 2 wires looked spliced in so i wipped off the side case an sure enough the 2 wires were solderd in so i changed my side case while doing the starter clutch to keep the wires correct.put it together an bang no problems fired up and ran like a dream i was over the moon with it......at this stage of the project she needed paint an few ajustments after 2 weeks of driving it wit out a miss so out comes motor and every nut an bolt ......paint on, every bushing replace looking good.... time for motor to go back in after a full satin black an polished head .wired up an ready to fire so bang an click is all i get .hour or 2 scratching the head fixed it bad connection cause of problem.so bang i go again an she cranks.spark plug is out at this stage so i check for spark an nothin.im scratching my since last week an still no spark .....the wiring consists of no diodes no fuses.it has an on/off switch from cdi to coil ...starter button from battery to solenoid 3 wires from motor stater to rect/reg .2 wire from pick up coil to cdi and a manual fan switch wired to the battery......and bang in middle of that nest of wires a black box/cdi with SUZUKI on it.....i have 3 battery pole connectors one big one to the solenoid an one wit 4 wires and the other wit 5 that connect direct to the battery...........dont know wat to do at this stage an i was wondering if any body out ther could tell me wher needs to be earthed apart from the battery? why hav i no spark now an before it was sweet.....was going to try get a cdi but what do i do get one wit a suzuki badge on it ....
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post #2 of 17 Old 10-24-2013, 06:22 PM
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"Frankenbikes" aren't uncommon; a "Frankenengine" may be!

Don't know the vintage of the engine; pre-2008 would have a CDI powered from alternating current from exciter coils of stator; 2008 or later would have an inductive ignition powered by 12 VDC.

Long-distance diagnosis remains difficult under the best of conditions; the lack of detail on the model and configuration of your engine makes things more difficult.

Regrets I can't be helpful; maybe other inmates can suggest helpful approaches. Good luck!
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post #3 of 17 Old 10-24-2013, 06:25 PM
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Dayum, my head hurts after reading that !!!

Maybe one thing at a time Chin.

Damocles to the help desk please.

Gray-haired riders donít get that way from pure luck.

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post #4 of 17 Old 10-24-2013, 06:26 PM
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Ha, beat me by three minutes.

Gray-haired riders donít get that way from pure luck.

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post #5 of 17 Old 10-24-2013, 11:22 PM
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Did you happen to take a photo of the stator while the cover was off?

As was stated, we need to work out whether you have a Gen1 or Gen2 engine.
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post #6 of 17 Old 10-25-2013, 03:45 AM Thread Starter
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thanks to all for the replies and sorry for the lack of detail........the motor is for sure pre 07 engine number is kl650ae013820.....it seem s to me out of the cluster of 5 wires from the engine the red and white one is for the pulse,on my motor these red an black wires are cut taped up not in use and in its place some genius ran another 2 wire into the system.....theory suggest that some sort of problem occurred an instead of changing the stater it got me two seprate wires for pulse........at the moment im not getting a reading from these wires when cranked before they get to cdi.......i have the battery negitive grounded and no other ground .....can anybody tell me do i need to ground anywher else that may be causing my problem no spark?.........any input is greatly appreciated at this stage ......i dont want to take engine out an strip down the side of her to find no problem and that i over looked a ground wire or somethin ......
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post #7 of 17 Old 10-25-2013, 04:28 AM Thread Starter
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another thing im questioning myself with is,on one of the connections to the battery i have a blk/y wire from battery to rect/reg..,1 batt to starter solenoid.....1 from batt to cdi ..and 1 to fan switch.......on the other connection to the battery i have a white wire from batt to rect/reg and a brown/white one batt to rect/reg....1 wire to on/off switch....1 wire to fan switch and one to starter button back to solenoid......out of these 2 clusters witch goes to the positive terminal an which to the negitive.....ther are no markings on the connectors and im wondering do i even hav them in the right place?and thank you again for your replies this is very fustrating so close but yet so far
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post #8 of 17 Old 10-25-2013, 04:52 AM
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the chin, without discernible wiring diagrams, or photographic images, of your lash-up, I'm dismayed to considerable extent in offering any meaningful advice or guidance.

Best I can do is share with you Mr. Clymer's wiring diagrams:





Again, wish I could be more helpful.
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post #9 of 17 Old 10-25-2013, 06:09 AM Thread Starter
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thank you damocles.......i have no diodes or relays an my wiring in no way the same so it looks like im snookerd when it comes to the diagrams.ther are two wires from my cdi one goes to an on/off switch and on to the coil the other wire on the coil is straigh to the battery which terminal + or negitive is wat im trying to find out to determend which battery lead go wher.the other wire from cdi goes to the oppisite battery terminal to the one wit the coil straigh to batt.........apart from that if i leave the starter circuit working to crank engine an take the pulse wires before they enter cdi should i get an AC reading from these wires when i crank regardless ?
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post #10 of 17 Old 10-25-2013, 07:59 AM
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You should get AC readings from the pickup coil, the exciter coil, and the power coils of the stator when the engine is cranking, IMHO.

Without AC from the first two, engine won't run.
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