Frustrated - Kawasaki KLR 650 Forum
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post #1 of 2 Old 12-12-2017, 07:36 PM Thread Starter
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Join Date: Dec 2017
Location: St. John's, Newfoundland, Canada.
Posts: 1
Frustrated

I am seeking some advice with regards to a mechanical issue that I have been unable to resolve with my 2015 Kawasaki KLR 650.

The KLR has a little over 3000KMS on it and has never been driven hard or abused. In September of this year, while driving it the following things occurred:
-It intermittingly lost power, backfired, stalled.
-It re-started, would run a short time and then stall again.

Once I got it home in my garage, I tried to figure out what the issue was. I thought the wires may have gotten wet as I had washed it a few days before, however the water pressure was very low and I was careful to avoid wiring. The bike is always stored inside and on trickle charge when not in use for long periods. I began to document what action I took in an effort to be thorough in analyzing the issue. After much effort and expense in purchasing replacement parts, and still no luck, I brought the bike to a reputable motorcycle mechanic. Here is a list of everything that I and the mechanic done to find the problem:

Fixes:

2017-09-20 to 22ND
-Sprayed wiring harness and all electrical connectors with “wire dryer”.
-Replaced Spark Plug.
-Removed Carburetor/ stripped and cleaned as per step by step instructions on Youtube.
-Re-Installed Carburetor. The bike started after 3 attempts, ran 5 minutes and then stalled again. It re-started first try after it stalled. I let it run another 25 minutes without it stalling.
Re-started a few more times with no problem. ALL SEEMED OK.

2017-09-23
Attempted to start next morning. WOULD NOT START!
Fixes:
-Inspected all electrical connectors. All appeared OK.
-Inspected Ignition Coil/ Appeared OK but ordered a new one on-line.
-Cleaned Air-box and Filter as per Youtube video. NO START!

2017-09-26
Fixes:
-Inspected Stator as per instructional video on Youtube. Appeared OK.
-Tested to see if Spark Plug was sparking. NO SPARK going to plug!

2017-10-04
-Received new Ignition Coil and installed. STILL NO SPARK!

2017-10-05
-Checked Battery/ All good 12.23 Volts. Tried starting with clutch depressed and also with kickstand up. NO Spark!

2017-10-06
-Removed and Inspected/ Starter Relay Solenoid & Fuse. Starter Relay (Denso 058700-4000) and Igniter also inspected for visual damage. All looked in tact but was unable to confirm if they were functioning properly.

2017-10-17
-By-passed Kickstand Safety Switch. Still NO SPARK! Engine compression and fuel flow seem to be fine.
-Bike re-assembled. Tank/ Seat and Panels left off.

2017-10-24
Brought the KLR to Avalon Powersports Ltd. The mechanic completed the following:
-Checked power from Starter Solenoid.
-Checked spark/ none.
-Checked Wiring Connections/ all OK/ added dielectric grease to them as they were reassembled.
-Tested Trigger Coil, 110 Homs approx., no continuity to ground.
-Checked Plug Cap, approx. 5000 Homs resistance.
-Checked for 12 Volt to Coil/ OK.
-Eliminated Kill Switch on side stand with jumper/ No difference.
-Checked for continuity from CDI Plug to Trigger Coil, Ignition Coil, battery positive and negative/ All OK.
-Replaced CDI Unit/ no difference.
-All testing done with a fully charged battery.


If anybody has had a similar issue, or can offer some insight, I would appreciate it.
Macker12 is offline  
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post #2 of 2 Old 12-12-2017, 08:25 PM
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Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,467
I do Not read that you or the other mechanic measured the AC voltage output from the trigger coil.
Needs to be a consistent .1-.2 VAC or above at electric starter speeds. (Not in the books.)

And even then, I've been fooled at least once, maybe twice!

pdwestman
Modify at "YOUR OWN RISK"!

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