Klr 600 No Spark :-( - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

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post #1 of 3 Old 10-29-2015, 05:35 AM Thread Starter
Join Date: Oct 2015
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Klr 600 No Spark :-(

Im new to this Forum - Im usually a KZ1000 driver so use to working on old bikes/wiring... but wanted a more funny bike - but maybe not the best option :-(

I bought a KLR 600 from 1986 from a friend, it has no spark so have been googling the internet thin about this...
He changed the coil and CDI (with an aftermarket from ebay) but still no spark..

-The black/yellow is frame and the Red/black i framed (around the diodeboard)
-I dismounted the Blk/W wire going to the Kill switch
-When i Ohm the starter/coils its seems like its within the specs
-But what i dont understand is the red and white wire coming from the exciter - the red gives me 3V and the white gives me 22V - shouldnt they be 12V ???

The wire to the coil gives me 0.1-200 AC when spinning the engine

Im lost :-(
larslykkegaard is offline  
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post #2 of 3 Old 06-10-2016, 07:51 PM
Join Date: May 2016
Posts: 2
i got them same thing i been a bike tech for 30yrears got me oug
blazing_bikes is offline  
post #3 of 3 Old 06-10-2016, 09:35 PM
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Join Date: Jan 2011
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The exciter coil windings should produce a voltage much greater than 12 volts, but . . . ALTERNATING CURRENT.

Do you get a pulse from the pickup coil?

Rather than cut wires to the kill switch, I'd recommend checking the continuity of the wires indicated by the ignition switch matrix on the KLR650 wiring diagram (Google bold print to view a copy; KLR600 ignition essentially identical to that of the Generation 1 KLR650, AFAIK.).

So . . . with adequate alternating current from the exciter coils to the CDI, a pulse from the pickup coil to the CDI, and operational CDI and ignition coil, spark will occur. The kill mechanism is grounding the CDI power lead, by either the kill switch or the OFF ignition switch position; a continuity check should tell you whether an incorrect grounding of this vital voltage is occurring.

The pickup coil lead to the CDI passes perilously close to the countershaft sprocket; continuity/short circuit may be an issue here.

I think a wiring diagram and a multimeter are your friends in this case.

(Comments from my experience/opinion; corrections/clarifications welcomed from the readership!)

This link leads to a reasonable CDI tutorial: https://4strokes.com/viewtopic.php?f=58&t=7

Last edited by Damocles; 06-10-2016 at 10:23 PM.
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