Ignition issues? - 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 7 Old 06-25-2019, 09:27 PM Thread Starter
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Ignition issues?

Ok guys, finally found a carb, and fixed all the issues from the previous owner(I thought). Haven’t had much time but still managed 75 miles on it. This 85 klr600 had been sitting 20 years or more. It runs great until I really get on the throttle hard. It up and dies and tach goes to zero like I turned the switch off. Turn the ignition switch off and back on, and it’s back on. If I stay at 1/2 throttle or less and below 5k rpm’s it doesn’t miss a beat. Any ideas? CDI box? Ignition switch? Bypassed the kickstand switch and same thing.
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post #2 of 7 Old 06-26-2019, 09:48 AM
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Check all connections you can in the battery circuit; + 12 VDC and ground. Suspect interruption of main power from intermittent "OPEN" or "SHORT." Take a look at the fuse connections, clips and wiring, also.

You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, youre gonna be dead. "John Russell" (Paul Newman), Hombre
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post #3 of 7 Old 06-26-2019, 12:57 PM
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Originally Posted by Damocles View Post
Check all connections you can in the battery circuit; + 12 VDC and ground. Suspect interruption of main power from intermittent "OPEN" or "SHORT." Take a look at the fuse connections, clips and wiring, also.
Huh? The CDI is not connected in any way to the 12V circuit. Did you overlook "KLR600"?

The CDI is powered by the 2 Exciter coils on the stator and then the CDI is tripped by the separate trigger coil positioned along the outside perimeter of the flywheel, at about the 8:00 position on a KLR600 if I remember correctly.

Ryanmcintire, Will the engine accelerate at full throttle from idle to 4500 rpm? If so I'll concur that it is not carburation.
So I think that you are on the right path IMO as to the probability of a failed/failing CDI unit. Which might be a near extinct species.
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post #4 of 7 Old 06-26-2019, 02:08 PM
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What I have learned with regard to the Gen 1 ignitions is that any wiring coming out of the alternator cover is suspect after about 10 years. I have found very brittle insulation where the wires exit the cover and enter the channel in the case, right at the countershaft sprocket. Some have had the insulation falling off the wires, some wires have been broken inside the insulation.

I don't know what causes this embrittlement at this point I don't see it elsewhere in similarly aged harnesses. Inside the case it is heat and oil but, outside the case, it may have something to do with the type of chain lube used. IONO.

Long story short, it is worthwhile to check those wires for integrity.

Tom [email protected]

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post #5 of 7 Old 06-26-2019, 03:00 PM
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Originally Posted by pdwestman View Post
Huh? The CDI is not connected in any way to the 12V circuit. Did you overlook "KLR600"?

The CDI is powered by the 2 Exciter coils on the stator and then the CDI is tripped by the separate trigger coil positioned along the outside perimeter of the flywheel, at about the 8:00 position on a KLR600 if I remember correctly.

Ryanmcintire, Will the engine accelerate at full throttle from idle to 4500 rpm? If so I'll concur that it is not carburation.
So I think that you are on the right path IMO as to the probability of a failed/failing CDI unit. Which might be a near extinct species.
How right you are!

Senility (in myself), I find, remains CRUEL!

You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, youre gonna be dead. "John Russell" (Paul Newman), Hombre
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post #6 of 7 Old 06-27-2019, 02:28 PM Thread Starter
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Thanks guys, I’ve figured out it’s rpm related. Above say 6.5k it starts to break up and then dies. I can wot in any gear and it’s fine if I shift at 6k it never misses a beat. Wandering if it’s possible it’s overcharging at high rpm and causing the issue. Guess I’ll check it tonight and post an update.
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post #7 of 7 Old 06-27-2019, 08:38 PM
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Ryanmcintire,
I've never known an ignition stator, Exciter Coil to be ABLE to over-charge a CDI unit.

The 12 volt battery, rectifier/regulator, electric start and lighting system is TOTALLY separated from the ignition system on your '85 KLR600 & on all '87-'07 KLR650's.
You may dis-connect the battery & the 3 yellow wire connector from the stator, kick start it and test ride it, if you wish.

I'll again suggest that your bike has a failing CDI unit.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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