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Discussion Starter #1
Hi all, this is my first post as I'm new to the KLR world. I recently got a 2002 KLR650 and everything was good for about a week. I got off the bike and parked it and the next day it would not spark again. It spins over fine but no spark coming from the plug. I cleaned the kill switch and did the bypass on the clutch and sidestand and nothing. I have power going in to both sides of the coil but no fire at the end. Does anyone have any ideas on this, I love the bike but all I do is work on it for the last 2 weeks. Any help would be greatly appreciated. Thanks
 

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I hope the coil didn't cook itself out. That's my only guess.

The good news is these bikes are very reliable with minimal upkeep and
maintenance. Replacement parts are usually cheap. Over the long
term you should be VERY happy with your KLR.

2 Fast,
I just went thru my troubleshooting guide in the factory SM and with the new generation ignition, I
couldn't come up with a starting point for you to trace the problem down.
The listings were, and I hope this can help:
Battery voltage low
Plug dirty, cracked, or maladjusted
Cap or cap lead shorting
Wrong plug
Neutral switch, sidestand switch, or interlock diodes problem
Crank sensor faulty
Ignition or stop switch shorted
Coil faulty
Main 20 A fuse blown

Roughly same stuff listed for weak spark condition too.
 

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Electrical diagnostics is known in some circles as a "Black Art". It is even harder when the bike is one place, and I am in another.

The above is my way of saying "I'm at a bit of a disadvantage at something that is tough with no disadvantages".

Look here and see if we can get on the same page:

http://www.bigcee.com/faq/KLR650-color-wiring-diagram.gif

In the upper right of center of the schematic, find the ignition coil.

In your tests at the coil, where are you finding readings, and where are you finding none?

Or, tell me what you are finding at the coil.
 

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Discussion Starter #4
Thanks for the help. I have worked with it for the last few hours again and nothing. I can tell you that for some reason if I unplug the 2 wires going to the coil and test them separately the ground wire (yellow/black) is hot, and the positive wire (solid black) has nothing. When I plug them back to the coil it makes a complete circuit because the positive wire becomes hot at that point, so I'm going to assume that the coil is good. I'm pretty good with wiring but this is crazy. I have checked all the relays and am really getting stressed and at my age I can't afford a heart attack yet....lol

Thanks again guys
 

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The trigger voltage to the coil to "fire" comes from the CDI. Have you examined anything at that component?
Go over your grounds again, in particular, from the safety bypasses.

Things are indicating a CDI issue. However, typically that component is prone to fail when warm / hot. You indicate that the bike was rode in, parked. Keep wiggling, jiggling and testing.
 

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You have probably checked this but is the on/off switch on the bars in the on position. I spent hours one time tearing another bike apart because I didnt have spark one mourning after it ran fine the night before. I finaly noticed I must have hit the kill switch as well as turned off the key.
 

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Discussion Starter #7
I have checked the safety switches, and the kill switch. I did trace the problem today more. When the bike spins over there is no power coming from the wires where the magneto is. I think maybe inside the cover is a pick up coil that I think should be hot when the motor is spinning over. All 5 wires that plug into the main wiring harness from the magneto have no power. There are 3 solid yellow wires, a black/white wire, and a solid red. One of these wires should get power when the motor spins over, right?
Sorry for being a pain guys but I would really like to ride this weekend if I can get this fix, so throw any ideas any one has at me and I will try it.
Thanks again
 

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Under the counter shaft sprocket cover you will find wires at the 9 o'clock position from center of sprocket. They have been known to get tangled up in the chain / sprocket. Three bolts with a 10mm head will confirm or dismiss...
 
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