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Discussion Starter #1
Hallo all, i have been a pround owned of a KLR 650 C for the past 2 years. My model is the 99

After a long break cause of winter i went yday to buy some new and fresh oil, filter so i can be ready for summer trips. She fired up at once, everything smooth, and after 1-2 mins of warming up o went str8 to the store. And then... the problem started.... No spark... all lights working, the engine cranks, everything as usual... but no spark....

back to the garage this morning, strip down project. Took out tank etc so i can have access to the electronics. Everything seems ok, checked all groundings, checked coil-cdi connections. Checked everything that i know about. Checked 3 new spark plugs . Is there any way to check the coil and the cdi ? With a voltmeter etc?

1.already check the plug to ground ..no spark from the plug.
2.check safety swicth ok.
3.check the stand switch ok.
4.already replaced new plug and bettery.
5. checked clutch switch.
 

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Service manual has resistance checks for CDI connections, ignition coil, pickup coil . . .

Wiring diagram (on 'Net) shows ignition switch and stop switch connections. With stator exciter coil voltage to the CDI, should get spark.
 

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Neuton,
Is there by any chance, any wire damage by the engine sprocket?

IME, lack of AC voltage output from both the exciter coil which powers the CDI and pickup coil which triggers the CDI is more likely than an actual failure of the CDI unit itself.

Give this thread a read,
http://www.klrforum.com/1987-2007-wrenching-mods/55225-need-help-albany-ny-bike-wont-start-just-cranks.html

We gave Ilya lots of help, but I feel he was not very good at following our guidance.
Post #22 for pickup coil.
Post #31 for exciter coil.
 

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Discussion Starter #4
Service manual has resistance checks for CDI connections, ignition coil, pickup coil . . .

Wiring diagram (on 'Net) shows ignition switch and stop switch connections. With stator exciter coil voltage to the CDI, should get spark.
Unfortunately since the bike is second hand i dont have the manual, searched web for it but no luck till now. I Was having the wiring diagram printed next to me while i was checking the whole wireness. What i didnt knew is that if the Stator exciter coil fails, i will never get a spark? thaught it was only there to charge the battery but on a second look on diagram i can see ur point ( dumb on electronics ).
 

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Discussion Starter #5
Neuton,
Is there by any chance, any wire damage by the engine sprocket?

IME, lack of AC voltage output from both the exciter coil which powers the CDI and pickup coil which triggers the CDI is more likely than an actual failure of the CDI unit itself.


We gave Ilya lots of help, but I feel he was not very good at following our guidance.
Post #22 for pickup coil.
Post #31 for exciter coil.
Well the wireness above the sproket seems fine, gave it a second look after u suggested it. I will check tommorow the readings on exciter coil, cdi, coil etc as people said in the forum u linked. thx a lot for ur help guyz.
 

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Discussion Starter #6
hallo again, i remove the stator side case and inspect the Exciter coil. I was wandering, i have to check the ohms there While the green wire is not grounded right?

Also this strange thing happens, i have checked the 2 wires that is going to the coil after the cdi with the volt meter, it goes around 12 and then droppin at 2-3. Is that normal ?
 

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hallo again, i remove the stator side case and inspect the Exciter coil. I was wandering, i have to check the ohms there While the green wire is not grounded right?

Also this strange thing happens, i have checked the 2 wires that is going to the coil after the cdi with the volt meter, it goes around 12 and then droppin at 2-3. Is that normal ?
Neuton,
I'm disappointed in you already. Neither Damocles or myself made any suggestion about Removing the Engine Cover.

You can not crank the engine over with the Electric Starter with the starter gears Un-supported! :nono:

Here is part of Our Problem, USA never got the "C" model. So most of us don't have a service manual for the KLR650-C model either.

The USA model KL250-G Super Sherpa had a stupid KILL Switch which would allow the starter motor to crank with a Dead Ignition! Any chance the KLR650-C model allows the same error?
If the engine cover is still removed, carefully remove the reduction gear clusters, there are flat washers on Both sides of Both gear clusters. Don't drop them in the engine or lose them. With the gear clusters removed you can try the Starter Button with the KILL Switch ON & OFF.
 

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Discussion Starter #8
Neuton,
I'm disappointed in you already. Neither Damocles or myself made any suggestion about Removing the Engine Cover.

You can not crank the engine over with the Electric Starter with the starter gears Un-supported! :nono:

Here is part of Our Problem, USA never got the "C" model. So most of us don't have a service manual for the KLR650-C model either.

The USA model KL250-G Super Sherpa had a stupid KILL Switch which would allow the starter motor to crank with a Dead Ignition! Any chance the KLR650-C model allows the same error?
If the engine cover is still removed, carefully remove the reduction gear clusters, there are flat washers on Both sides of Both gear clusters. Don't drop them in the engine or lose them. With the gear clusters removed you can try the Starter Button with the KILL Switch ON & OFF.
I know u u didnt suggest to remove the engine cover but in the links u gave me this guy might have problem with the woorduf key thing and i was wandering if i had the same problem. I decided to inspect the stator and the trigger coil because i have an extra spare of gasket for it and it was like 30 mins job.

No i dont have the kill switch u mentioned. My wire hireness is allmost identical with this 1 u can find easily at web. Except some small differences special on lights/tachometer ( since c model doesnt have tacho ) . Everything else is identical

Test the ohms of the pulse coil/trigger coil. BK/Y - BK 100-150ohms. 144ohms, done
Test the 2 wires to ground, should be infinite! infinite, Done
Im having the feeling that maybe my Cdi is failing. for some reason when i start cranking it goes 12V and then dropping stadily to 3-4V. ( the 2 wires before the coild, BK-BK/Y)
Unfortunately there are allmost no KLR's in Greece so i cannot find a CDI to test :(
 
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