Wiring Loom Rebuild, coolant leak?, and Hi
Hello everybody, I am very excited to be here! You see I've been waiting my whole life to have 4 wheelers and motorcycles, but due to school, career, family, and wife, I've never completed my ambitious dream...until now. Last year for Christmas I bought a 1989 quadzilla 500 four wheeler (built in 2014), a 1991 Polaris 350, and last week I bought a 1987 Kawasaki KLR650 (POS). I say POS, but I'm very fond of all my POS's.
Unfortunately, I've had the most problems with the Polaris and the KLR. I blew the engine in the Polaris when it was running it's best. (piston actually destroyed itself by somehow overextending past normal travel and crashing into the case destroying it backwards.) The KLR had a new battery, but would die on 1 mile journey. (wife hated it real fast). I got the battery charged, coolant changed, oil changed, seat redone, and bought a jump box and strapped it to the KLR. All was well until the road I was on ended and the headlights were so dim I couldn't see it. I crashed my KLR on the maiden voyage without a helmet, cell phone, or brain. (I told you I was excited)
Anyways, now that I had to limp 3 miles home at 2:00 in the morning, my motto changed from "getter done" to "get it done right" With that in mind, there's so much wrong with this bike, I might not ever get to ride it. That's when I started to research and found this forum. So hopefully you guys have been there done that. From the posts I have read so far, my bike has common problems. The wiring caught on fire the night I crashed it (wouldn't start after I crashed so I poured some gas to "prime" it)boom!, so I took the entire loom off saving the connectors. Now my problem is that I'm needing a wiring diagram. I have one already that is color coded, but the colors are different than mine, so ???? Really I would rather wire up one system at a time. Starting with the battery, starter, ignition switch, and CDI box. From that project line-up I'm down to the CDI box. Does anyone have a grip on the different colored wires? I tested the circuits and the solid red wire is grounded. solid Black wire is also grounded. red with blck stripe open. black with white stripe open. Then there is a green wire that looks like it tests on off on off with the turning of the engine, so im guessing that is the trigger for the coil. The problem is that there isn't a green wire going into the CDI box.
I really need the CDI master mechanic to message me or call me on my cell 7022922480. I live in Las Vegas. Thanks in advance to whoever is the wiring guru who can save my ass right now so i can fix this before my wife kills me.(I've been in the garage non-stop for days) I will buy you some beer or somehow make it worth your trouble. I guess I could find another loom, but I don't think any wiring that old is going to be in great shape and worth my money, so I'd rather just make a new one.
Besides the wiring nightmare from hell, the KLR is also spitting out liquid from the exhaust manifold port (at engine) I had suspected fuel, but I think it might be coolant. Honestly, it doesnt smell or look like either. Looks like water if you ask me, but has an oily characteristic when you rub it, yet doesn't smell or have any color that I could see. I did have to flush the radiator and coolant system when I found a few floating oil drops. Thinking head gasket I pulled the plug to find....nothing. Now when I took the exhaust off to replace starter wires, I turned over the engine and saw the spitting of the ?????? whatever it is. Guessing that it is coolant, oil, or fuel, but maybe a combo of all of them.( now you understand POS) Its my POS though, so if you know anything about spitting fluid out exhaust port or wiring a CDI box, please respond.