QuestionQUESTION: I am getting no spark to my spark plug on my KLR. I just bought this from a friend and he claims it has a new coil, stator, and stop switch which was broken I assume. I took the cover off the left side and inspected the stator and it looks good. I looked at the new coil and it looks new like the stator. Also I have checked every wire (without pulling off all the duct tape on the wires on the bike). The previous owner thinks the no spark issue started with the stop switch that was replaced but it seems to work good and is new as they describe and the plug matches up with no extra wires like its the wrong one or something. So my question is where would you go from here? I was thinking of buying a new stator and coil to make sure they are not the culpret. I keep a battery tender on it and it kicks over like it wants to start but has no spark.
ANSWER:
Hi Russell,
The early and later KLR have different ignition systems so testing them
has to be very different. Your bike is right on the line
where the ignition changes were made.
The older version uses a charge coil in the stator to power the CDI unit
while the later one uses a battery powered ignition coil.
One thing you can check is the side stand switch for on/off operation.
The red wire on older models was the power wire to the CDI.
If this is rubbed though and shorting the bike will have no spark.
If you can send me the CDI wire colors I may be able to help better.
Some kill buttons or switches must allow power through while others
do not. Check with the switch on and off to see if
you get any spark either way.
The clutch has a switch which can also be checked for on/off operation.
Clean all the connectors and look for bent pins on the CDI unit.
The stator charges the CDI on old models and then the crankshaft position
or pickup pulse coil triggers the voltage to the ignition coil at the correct time.
The pickup coil should have a small voltage pulse when starting.
If you let me know the wire colors I may be able to sort out which tests
are relevant to your bike model.
WS
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---------- FOLLOW-UP ----------
QUESTION: Thank you very much for your help. I found the CDI box and it did have a wire that was touching on the connection and needs clamped back on its end again but this didn't seem to get spark to it as yet. The CDI box is CD3606 and has one six section plug and another two prong plug with another single plug. The six prong plug (only using five sections) has two red wires with a black and a white wire and then a white wire with a black stripe. (The white one with the black strip was 90% separated from the plug I mentioned). Also key switch and stop switch work good and do what they are suppost to do but the kickstand switch is cut off from above the kickstand and wraped/tied togather.
AnswerHi Russell,
Here is some info that might help in tracing down a fault.
Red wire goes between CDI unit and stator.
Black wire on CDI is grounded on black/yellow frame ground.
Red/black on CDI goes to a diode box where it is either grounded or not
depending on the safety switches.
White on CDI goes to stator and also to ignition switch.
Black/white on CDI goes to black on ignition coil and to tachometer.
CDI blue/red goes to black/red and to pickup coil
CDI red/green goes to black and to pick up coil.
Disconnect the pickup coil from the CDI and
check for a pulse of voltage between the
pickup coil wires when cranking the engine.
Should have a 1 volt or more pulse of voltage
used to trigger the CDI discharge to the ignition coil.
Check all the above connections as best you can.
The red CDI wire should have some voltage
as well when cranking.
The ignition switch may ground out the white CDI
wire to stop the engine. The wire at the switch will
be black/white and should not be grounded with
the switch on.
The black/white CDI to ignition coil black wire
may be very high voltage when working.
Set your meter high on AC volts if trying to get a reading
there. It might just be a quick pulse but much higher
volts than the pickup coil.
You might try disconnecting the CDI red/black to the diode
box to see if that helps. Sometimes the diodes can leak
and ground out the ignition.
Let me know if you need other info.
WS
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