Join Date: Dec 2017
Location: St. John's, Newfoundland, Canada.
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:
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.
Attempted to start next morning. WOULD NOT START!
-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!
-Inspected Stator as per instructional video on Youtube. Appeared OK.
-Tested to see if Spark Plug was sparking. NO SPARK going to plug!
-Received new Ignition Coil and installed. STILL NO SPARK!
-Checked Battery/ All good 12.23 Volts. Tried starting with clutch depressed and also with kickstand up. NO Spark!
-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.
-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.
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.