Well, for what it's worth, attached is the trouble shooting appendix from my KLR650 Service Manual that refers to "no/weak spark". Bear in mind, I have a 2016 (manual), though it may be useful. :smile2:
The Generation 1 (pre-2008) KLRs have CDI ignition, unlike the latter-day models.
For spark on a Generation 1, you must have: Alternating current from the exciter coils of the stator feeding the CDI unit, recurring pulses from the pickup coil triggered by the timing lump on the rotor (flywheel), and an operational ignition coil.
You can measure exciter coil AC when the engine is rotated (remove the spark plug and grind it with the starter). You can monitor the pulses from the pickup coil. You can check resistances on the CDI terminals, and the ignition coil.
You can check connections for continuity/short-circuit; the kill mechanism is shorting the exciter coil voltage to the CDI by kill switch or by ignition switch in the OFF position.
Good luck; Google "KLR650 wiring diagram) for a running start at your problem.
And, perhaps to save you some time and effort: The battery, and its charging circuit, have absolutely positively completely NOTHING to do with the ignition on a Generation 1 KLR. Don't even think about charging or replacing your battery in hope of success with the "no spark" problem.
If you can find the plate with the vehicle identification number (VIN), or perhaps the documentation ("Title," or "Registration Certificate" over here), the model of motorcycle may be identified, if your mates can't assist you in identification.l
Just wondering if anyone has fitted a twin disc set up on a kl650 and if so what ohter set up would fit.
I am trying to change my 650 a bit with twin disc and some mods all over the bike.
Also what about the exhaust,give me please some more one cylinder sound.
Safe riding and be in front.
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