Spark - no Spark, please help - 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 13 Old 12-02-2010, 10:39 PM Thread Starter
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Unhappy Spark - no Spark, please help

I have a 1989 KLR650 that will start some times and the next time I try to start it has no spark. It has the neutral and side stand bypassed, and all of the connections cleaned and checked etc. I am guessing it may be the coil or the CDI box, but I am not sure. Does the coil or the CDI box start and stop working? and is there a easy test for ether one? If anybody has had this problem please let me know.
The only other thing wrong with the bike is the neutral light does not work. I have replaced the neutral bulb and the switch and have a signal from the switch to the diode. Could this be a problem with the starting?
Thanks for any help with this problem
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post #2 of 13 Old 12-03-2010, 09:21 AM
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Raven -

I'm going to guess that you have a ground fault somewhere. The CDI and coil should not be intermittent - they should just fail.

If you can, reverse the clutch and side stand bypasses to see if they are the culprit. If you didn't do them then they may not have been done well and reliably.

Check all of your ground connections to make sure that they are clean and tight. Your neutral light problem seems like a grounding problem.

Inspect the main harness from the front of the bike back to the seat, looking for chafed areas where the wires may be shorting against something.

Does the bike ever stop running after you've started it?

Tom

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post #3 of 13 Old 12-03-2010, 10:03 AM
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Echoing everything Tom pointed out. I don't know if you are working from a diagram. I find it helpful to get all players on the same page.

http://www.bigcee.com/faq/KLR650-col...ng-diagram.gif

Clicking on the diagram will enlarge the area you click on.

A recent thread of similar problem

I would have little concern regarding the clutch bypass. The clutch safety acts as a starter interrupt. A malfunction with the clutch safety and you will have no starter engagement.

Side stand safety acts as an ignition interrupt. Problems there will allow the engine to turn over, and will prohibit the bike from firing or starting.

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post #4 of 13 Old 12-03-2010, 11:05 AM Thread Starter
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Thanks Vatrader, you have been a big help. Dan
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post #5 of 13 Old 12-03-2010, 11:16 AM Thread Starter
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Thanks Tom for the info, you have been a big help. The bike started missing once when I was riding it, but pushed thru it an kept running. How many grounds are there? To bypass the side stand you just solder the two wire together ? Thanks again Dan
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post #6 of 13 Old 12-03-2010, 12:46 PM
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Quote:
Originally Posted by Raven7777 View Post
Thanks Tom for the info, you have been a big help. The bike started missing once when I was riding it, but pushed thru it an kept running. How many grounds are there? To bypass the side stand you just solder the two wire together ? Thanks again Dan
Dan -

Egad, I'm not sure. There's a ground coming off the battery, one coming off the starter, a frame ground lead that is on the upper coil mount bolt, an engine ground lead...

Pull the tank off so you can see a lot of stuff. Start looking for wiring harness terminals. Loosen and then tighten every one that you can see, especially the ones associated with the coil. Grounds, positives, it don't matter. If it looks electrical, tighten and loosen it.

Oh, and this may be silly, but remove and firmly replace the coil lead to the spark plug - make sure that sucker is really clipped in.

Fixing intermittent problems is a real PITA, so you have to use the shotgun approach. Down side is that once you've fixed it you may not know what was wrong .

And yes, the side stand bypass is done by shorting the two main harness wires together.

Hope you get it solved!

Tom

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“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #7 of 13 Old 12-03-2010, 01:43 PM
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Look for wires and connectors like in this picture:



That black and yellow wire at the upper coil mounting bolt is a ground wire. Make sure wires like this are not broken, then loosen and tighten the connection to make sure it is secure.

Unplug and re-plug connectors like the one in the picture, again to make sure they are making good connections. A bit of dielectric grease in the connector is a good bit of preventative care.

This may be your suspect area, as it is the coil and regulator. Do the same for the Igniter module.

Tom

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 12-03-2010 at 01:51 PM.
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post #8 of 13 Old 12-03-2010, 01:48 PM
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After a little thought.....

You have a known neutral light issue....indicating possible ground problem...

Neutral safety is tied to both starter AND ignition, and if not properly grounded, COULD interrupt flow to CDI....

So...

I would start...

With the diode pack that is under the tank, up near the steering head.



This will eliminate switch shorts, goblins, etc. If this gets you spark, you can rig a permanent ground to the frame or to the battery.

If this does not bring joy, I would focus on coil...

And I know of no good way to test the CDI or any other electronic component on a KLR 650. They may read "OK", but when replaced, you get spark. Or not. YMMV.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]

Last edited by vatrader; 12-03-2010 at 01:51 PM. Reason: I kin spel. Its the typing thats hard
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post #9 of 13 Old 12-03-2010, 03:44 PM
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If it does turn out to be a wiring harness issue with many bad spots, I know of a good wiring harness for sale off a 99'. Hope you can find the short though.

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post #10 of 13 Old 12-03-2010, 04:30 PM Thread Starter
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Tom, thanks again for all of your help. I will let you know how it all turns out. I sure have learned a bunch about the KLR, but I still think it is an excellent around bike. Dan
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